Interlocking Concrete Block Wall System with Adjustable Leveling
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Solution Overview
Problem
The construction of concrete walls using concrete masonry units (CMUs) is a time-consuming process that requires skilled labor and precise positioning, as the consistency and strength of mortar significantly impact the quality and strength of the wall, making it complex and labor-intensive.
Innovation Solution
A wall construction system that uses leveling blocks with adjustable height and a spline and keyway connection, along with field blocks and beam blocks, which fit securely together without the need for a mortar setting bed, allowing for easy assembly of level and plumb courses by a relatively untrained worker.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional CMU blocks with mortar are used, then wall strength and bonding are achieved, but the construction process becomes time-consuming and requires skilled labor
Solution Approach 1:
The invention extracts and eliminates the mortar component from the wall construction system. Instead of using mortar for bonding and positioning, the system uses blocks with integrated mechanical interlocking features (protrusions and recesses) that directly connect blocks without requiring any mortar bed, thereby eliminating the time-consuming mortar application and positioning process while maintaining wall strength through mechanical engagement
Solution Approach 2:
The blocks are designed with self-aligning and self-leveling features including built-in protrusions and recesses that automatically guide proper positioning when blocks are stacked. The shouldered vertical edge portions and corresponding recesses create automatic mechanical alignment, allowing untrained workers to assemble walls quickly without requiring skilled judgment for mortar placement and block positioning
2Manufacturing precision
If mortar is used for positioning and bonding, then block positioning accuracy is achieved, but assembly time increases due to constant checking
Solution Approach 1:
The positioning and alignment features are pre-integrated into the block design during manufacturing. The shouldered vertical edge portions, recesses, and interlocking protrusions are built into each block before construction, eliminating the need for time-consuming现场检查 and adjustment during assembly. Workers simply stack blocks and the pre-built features automatically ensure proper alignment and positioning
Solution Approach 2:
The blocks feature self-aligning mechanisms where the shouldered edges and complementary recesses automatically guide blocks into correct position when stacked. This self-positioning capability eliminates the need for workers to constantly check and adjust positioning, as the blocks self-correct alignment through their geometric interlocking features
3Reliability
If skilled masons are used for wall construction, then quality and strength are improved, but labor cost and complexity increase
Solution Approach 1:
The wall construction system is designed to be self-explanatory and self-assembling through its geometric block features. The shouldered vertical edges, recesses, and interlocking protrusions provide intuitive alignment and connection without requiring skilled judgment or complex techniques. Any worker can assemble the wall by simply stacking blocks, as the geometry itself guides proper assembly, eliminating the need for skilled masons while maintaining consistent quality
Solution Approach 2:
The blocks are designed with uniform, repeating geometric features (shouldered edges, recesses, protrusions) that create a consistent assembly pattern throughout the wall. This homogeneity in block design allows any worker to follow the same simple stacking procedure for the entire wall, eliminating the need for skilled variation or judgment calls that different masons might make, thereby standardizing quality while reducing skill requirements
Data Source
AI summary
A wall construction system includes a plurality of leveling blocks arranged in a first course wherein each leveling block including an upper surface, a wall defining a leveling block void, and at least one leveling component having a leveling plate that engages the wall and at least one threaded adjuster extending through the plate. A plurality of field blocks is arranged in a second course atop the first course wherein each field block includes a lower surface that interfits with the upper surface of at least one of the leveling blocks and a wall defining a field block void aligned with the leveling block void of the one leveling block. A cementitious material is disposed in an aligned field block void and leveling block void of at least one of the field blocks and at least one of the leveling blocks, respectively.