Insulating Block with Segmented Mortar Walls and Rebar Through-Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermally insulating concrete blocks fail to provide adequate structural strength and continuity of longitudinal reinforcement while maintaining effective thermal insulation, often resulting in compromised performance due to horizontal deformation, high material costs, and inefficient heat transfer pathways.
Innovation Solution
The design incorporates strategically positioned thermally insulating material sections within cavities to lengthen the shortest path through the block material, reducing heat transfer while ensuring structural stability through connections between the front and back faces, and includes through-holes for rebar reinforcement to maintain structural integrity and reduce thermal bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insulating panels are placed in the mold before filling with mortar, then thermal insulation properties are improved, but the block is subject to horizontal deformation and compression under great forces and pressures
Solution Approach 1:
The block is divided into multiple cavities separated by internal walls made of mortar. These internal walls segment the insulating material into distinct sections, preventing horizontal deformation while maintaining thermal insulation. The segmentation allows the structure to withstand great forces and pressures without compromising the insulating panels.
Solution Approach 2:
Different parts of the block have different properties: the internal walls and connecting elements are made of strong mortar material to provide structural support and resistance to deformation, while the cavities are filled with insulating material to provide thermal insulation. This local differentiation of material properties resolves the contradiction between strength and insulation.
2Strength
If the block is made thicker to provide enough strength for structural support, then strength is improved, but building space is reduced
Solution Approach 1:
The block combines mortar material and insulating material in a composite structure. The mortar provides structural strength and load-bearing capacity, while the insulating material provides thermal insulation. This composite approach allows the block to achieve sufficient structural strength without increasing overall thickness, thereby preserving building space.
3Stability of the object's composition
If rebar runs through the insulating material, then continuity of longitudinal reinforcement is achieved, but the insulating material is easily damaged
Solution Approach 1:
The rebar is extracted from the insulating material and placed only within the mortar portions of the block. The mortar sections serve as conduits for the reinforcement bars, allowing continuous longitudinal reinforcement without compromising the insulating material. This separation protects the insulating material from damage while maintaining structural continuity.
4Stability of the object's composition
If an inner layer of mortar is added to provide a through-hole for rebar, then rebar continuity is achieved, but the block takes more space
Solution Approach 1:
The internal walls and connecting elements made of mortar serve multiple functions: they provide structural support, separate the cavities for thermal insulation, and simultaneously serve as conduits for rebar placement. This multi-functionality achieves rebar continuity without requiring additional space beyond the block's existing structure.
5Loss of energy
If webbing with thin walls is used to define empty inner cavities, then insulating properties are improved, but the block height is limited due to viscosity problems during filling
Solution Approach 1:
The formwork is designed with pre-positioned internal walls and cavity definitions before the mortar is poured. This preliminary structuring of the formwork allows the mortar to be poured in a controlled manner, ensuring proper filling of cavities and correct positioning of insulating material without viscosity-related problems, thereby enabling greater block heights.
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
This configuration enhances thermal insulation and structural strength, reduces material costs, and facilitates easier handling and production, while maintaining resistance to forces and pressures, thereby addressing the limitations of prior art in thermally insulating concrete blocks.
Implementation Method 1
the shortest path distance through the block material from the front face of the block to the back face of the block is longer (preferably at least 20%) than the distance from the front face to the back face for providing thermal insulation between the front face and the back face
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
An improved insulating block that offers great structural strength by having an interconnected block material structure with cavities filled with insulating material. The paths from the front face to the back face of the block through the block material are adapted to ensure an improved thermal insulation of the block, while providing a high load bearing capacity and allowing continuation of longitudinal reinforcement. This results in a block that can be easily manipulated and handled. Furthermore, the invention provides a method of manufacturing and a use of said blocks, and a wall or structure of said blocks.