Knockdown Insulating Concrete Block Web Structure
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Solution Overview
Problem
Existing insulating concrete form systems face challenges with costly transportation and tedious assembly of pre-assembled blocks, and lack of rigidity in unassembled knockdown blocks due to numerous connection points.
Innovation Solution
A knockdown insulating concrete block design featuring panels with alternating projections and recesses for interlocking, along with web structure assemblies including molded web inserts and bridges for enhanced rigidity and ease of assembly, allowing for efficient on-site assembly and improved structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If blocks are shipped in an unassembled condition (knockdown blocks), then transportation cost is reduced, but assembly becomes tedious and time consuming
Solution Approach 1:
The block is divided into separate components (panels and web members) that can be shipped independently and assembled on-site. The web members are separate from the panels during shipping, reducing bulk and transportation cost, but designed for quick connection during assembly.
Solution Approach 2:
The panels are pre-formed with embedded attachment couplings during manufacturing, so that when the blocks are assembled on-site, the web members can be quickly connected to the panels without requiring additional preparation or complex alignment procedures.
2Ease of operation
If blocks are shipped pre-assembled, then assembly is simplified, but transportation cost increases due to bulkiness
Solution Approach 1:
The block system is segmented into panels and separate web members that can be shipped in a compact, unassembled state, reducing transportation bulk and cost. The segmentation allows components to be nested or stacked efficiently during shipping.
Solution Approach 2:
The attachment couplings embedded in the panels serve as intermediaries that facilitate the connection between web members and panels. These couplings simplify the assembly process by providing pre-prepared connection points, making knockdown assembly as easy as pre-assembled blocks.
3Adaptability or versatility
If knockdown blocks have numerous connection points between web members and foam panels, then assembly flexibility is improved, but rigidity decreases
Solution Approach 1:
The attachment couplings are strategically positioned at specific locations on the panels where structural support is most needed. Rather than distributing connection points uniformly, the couplings are placed to optimize both the rigidity of the assembled block and the flexibility of the assembly process.
Solution Approach 2:
The attachment couplings are embedded within the foam panels, creating a composite structure that combines the foam material with the coupling mechanism. This integration strengthens the connection between web members and panels, improving overall block rigidity while maintaining assembly flexibility.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A web structure for connecting two foam panels comprising a pair of web inserts adapted to be molded in the foam panels. Each of the web inserts has an elongated end plate and a pair of central male connector members supported by the elongated end plate. A pair of bridges is connected to the web inserts so as to extend between the foam panels. Each of the bridges having a cross member, a first female connector member formed on one end of the cross member and a second female connector member formed on an opposing end of the cross member. The first and second female connector members each having a cavity shaped to matingly receive one of the central male connector members of the web inserts from a lateral side of the first and second female connector members.