Interlocking Concrete Masonry Units for Mortarless Wall Assembly

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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, involves complex positioning and cutting of blocks, and necessitates multiple types of blocks for stability and corner formation, making it costly and difficult for untrained workers to assemble effectively.

Innovation Solution

A wall construction system comprising interfitting blocks with multi-directional elevation patterns and recess patterns, allowing for staggered arrangement and easy assembly without mortar, including jamb, half jamb, and stretcher blocks that can be stacked in multiple orientations, along with leveling tools for precise alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional CMU blocks with mortar are used for wall construction, then bonding strength and structural stability are achieved, but assembly time increases and skilled labor is required

Engineering Contradiction:

Improvebonding strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent removes mortar from the wall construction process entirely. Blocks are designed with complementary geometric features (protrusions and recesses) that interlock directly without requiring mortar for bonding, thereby eliminating the time-consuming application and curing processes associated with traditional mortar-based construction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces geometric interlocking features (protrusions and recesses) as an intermediary mechanism between blocks. These features serve as a physical mediator that provides both positioning accuracy and bonding strength, replacing the traditional mortar intermediary while enabling faster assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If multiple types of CMU blocks are used for corners and jambs, then structural stability is improved, but system complexity and cost increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidsystem complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent designs a universal block type that can be used for all wall sections including corners and jambs. The block's geometric features and orientation capabilities allow it to perform multiple functions traditionally requiring different specialized blocks, thereby simplifying the system while maintaining structural stability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent enables blocks to be oriented in different directions (multi-directional orientation) to adapt to various structural requirements. This dynamic adaptability allows a single block type to fulfill multiple structural roles, eliminating the need for specialized corner and jamb blocks while maintaining stability.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If CMU blocks require cutting in the field, then wall configuration flexibility is achieved, but assembly complexity and time increase

Engineering Contradiction:

Improvewall configuration flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent pre-segments the wall structure into modular blocks of various standard lengths during manufacturing. This allows different wall configurations to be achieved by selecting and arranging pre-cut blocks rather than cutting blocks in the field, thereby maintaining flexibility while simplifying assembly operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs cutting and sizing operations during block manufacturing rather than during field assembly. Blocks are pre-prepared in various lengths and configurations before delivery to the construction site, eliminating the need for field cutting tools and operations while maintaining wall configuration flexibility.

Inventive Principle:

Principle #10Preliminary action

4Strength

If mortar is used for block positioning, then bonding strength is achieved, but positioning precision and assembly speed decrease

Engineering Contradiction:

Improvebonding strengthVSAvoidpositioning precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the chemical/mechanical mortar bonding system with a purely mechanical geometric interlocking system. Complementary protrusions and recesses provide inherent positioning precision through their geometric fit, eliminating the need for mortar-based positioning while maintaining bonding strength through the interlocking mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10934705B2Wall construction members and system

Publication Date: 2021.03.02 MAX BLOCK DEV L L C

AI summary

A wall construction system includes multiple block types that interfit with one another to form walls in a staggered arrangement. Block types include jamb blocks having front and back surfaces, a planar surface on a first end, and a second side having a projecting surface or a receiving surface configured to mate with the projecting surface. The jamb block includes a top mating surface and a bottom mating surface configured to mate with the top mating surface. Webs extend from the front surface to the back surface to form voids. A multi-directional elevation is formed over a void adjacent the planar surface to permit stacking of blocks in two orientations. Other block types include a half jamb block having a web to form a void and a planar surface, and a web stretcher having a projecting surface on one end and a receiving surface on another end.