Interlocking Masonry Brick with Stone Façade and Insulating Backing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Modern construction methods face challenges in maintaining structural integrity and aesthetics when using carved natural stone façades, particularly in thermally and moisture-insulated brick systems, due to constraints on construction and anchoring techniques.

Innovation Solution

The development of thermally and moisture-insulated bricks with a carved natural stone façade coupled to lightweight or massive concrete backing, featuring an intermediate moisture insulating layer and interlocking interfaces, allowing for efficient assembly and anchoring without compromising structural integrity or aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If carved natural stone façade is permanently anchored to support walls, then structural integrity and aesthetics are maintained, but construction constraints become significant and anchoring complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidanchoring complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The brick is divided into distinct functional segments: a carved natural stone façade layer for aesthetics, a concrete backing layer for structural strength, and an intermediate moisture insulating layer for protection. This segmentation allows each layer to perform its specific function without compromising the others, eliminating the need for complex anchoring systems while maintaining structural integrity and aesthetic appeal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges the façade, insulation, and structural backing into a single integrated brick unit. The concrete backing is directly coupled to the natural stone façade through the intermediate layer, creating a unified component that combines aesthetic, protective, and structural functions, thereby simplifying construction and eliminating separate anchoring requirements.

Inventive Principle:

Principle #5Merging (Combining)

2Shape

If carved natural stone façade is used, then aesthetic appeal is maintained, but thermal insulation and moisture resistance are compromised

Engineering Contradiction:

Improveaesthetic appealVSAvoidmoisture and heat transfer

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

An intermediate moisture insulating layer is introduced between the carved natural stone façade and the concrete backing. This intermediate layer acts as a mediator that provides thermal insulation and moisture resistance while allowing the natural stone façade to maintain its aesthetic appeal. The layer prevents direct contact between the stone and moisture-prone environments.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The brick employs a composite structure combining natural stone, concrete, and an intermediate insulating material. This composite design allows the system to exhibit properties of all constituent materials: the aesthetic qualities of natural stone, the structural strength of concrete, and the insulating properties of the intermediate layer, thereby addressing both aesthetic and protective requirements simultaneously.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If lightweight concrete backing is used, then ease of assembly is improved, but structural strength is reduced

Engineering Contradiction:

Improvebrick weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The concrete backing can be formulated with varying densities and strength parameters depending on specific application requirements. The patent allows for lightweight concrete formulations when ease of assembly is prioritized, and massive concrete formulations when structural strength is the primary concern, providing flexibility to optimize the weight-strength trade-off for different construction scenarios.

Inventive Principle:

Principle #35Parameter changes

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 solution provides enhanced thermal insulation, improved moisture resistance, and increased structural integrity while maintaining the aesthetic appeal of natural stone façades, addressing the constraints of modern construction methods.

Implementation Method 1

an intermediate moisture insulating layer sandwiched between the carved natural stone façade and the backing

Methodology Applied

Scientific EffectMoisture insulation: Absorption (physical)

Implementation Method 2

depositing a concrete mixture comprising cement to sand at a ratio of between 1:1 and 1:3

Methodology Applied

Scientific EffectCement bonding: Adhesive

Data Source

PatentUS10626599B2Interlocking masonry brick

Publication Date: 2020.04.21 NEGEV DAVID

AI summary

The disclosure is directed to thermal and moisture insulated interlocking brick comprising natural, in-situ carved stone façade coupled to a backing layer comprised of a massive and lightweight portions, as well as methods of forming the brick and methods for cladding and using the bricks in load bearing walls and in non-load-bearing walls (light construction).