Masonry Block with Auxiliary Voids for Continuous Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional masonry block designs retain thermal bridges between exterior and interior surfaces, and preformed insulation pieces often fail to form a continuous, air- and moisture-tight barrier due to termination at edges and reliance on physical abutment for interlock, which can be compromised in real-world construction environments.

Innovation Solution

A masonry unit design with a main portion and auxiliary portion that allows insulation material to flow between units, minimizing thermal bridges and forming a continuous barrier through interconnected voids, with bridging webs and auxiliary voids extending from top to bottom and between units to facilitate insulation flow and create a continuous thermal and moisture barrier.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If preformed insulation pieces are used in conventional masonry blocks, then insulation is provided, but the insulation fails to form a continuous barrier due to termination at edges and reliance on physical abutment

Engineering Contradiction:

Improvecontinuity of thermal and moisture barrierVSAvoidcomplexity of achieving continuous barrier

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The masonry block is divided into multiple cavities (first cavity, second cavity, third cavity) that are interconnected through internal passages. Each cavity can be independently insulated, but the passages ensure continuity of the insulation barrier across the entire block structure, eliminating gaps at edges and interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation material is nested within the multi-cavity structure of the masonry block, with cavities positioned at different levels and orientations. The interconnected passages allow the insulation to form a nested, continuous barrier that extends throughout the block volume, ensuring thermal and moisture protection without relying on external abutment.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If conventional masonry block designs are used, then structural strength is maintained, but thermal bridges remain between exterior and interior surfaces

Engineering Contradiction:

Improvestructural strength of masonry blockVSAvoidthermal bridge heat loss

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The masonry block incorporates localized insulation cavities strategically positioned at thermal bridge locations such as corners, edges, and junctions. These localized insulated zones interrupt heat flow paths without compromising the overall structural integrity of the block, addressing thermal loss specifically where it occurs most.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insulation material acts as an intermediary substance filling the cavities and passages within the masonry block. This intermediary layer breaks the direct thermal connection between exterior and interior surfaces, reducing heat transfer through the block while maintaining its load-bearing function.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If physical abutment is used to interlock insulation pieces, then insulation continuity is attempted, but the barrier is compromised in real-world construction environments

Engineering Contradiction:

Improveintegrity of moisture and air barrierVSAvoidease of achieving proper interlock

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The insulation cavities and passages are integrated directly into the masonry block structure during manufacturing, merging the insulation accommodation features with the block itself. This eliminates the need for separate insulation pieces requiring physical abutment and interlocking, as the continuous barrier is formed within the block's own geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cavities and interconnected passages are pre-formed within the masonry block during manufacturing, preparing the structure to receive insulation material in a way that ensures continuous barrier formation. This preliminary structuring eliminates the need for complex field assembly and interlocking operations, reducing reliance on worker skill and environmental conditions.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11091911B1Masonry block for in situ insulation application

Publication Date: 2021.08.17 SCHNABEL THOMAS JAMES

AI summary

A masonry unit may include a main portion having end surfaces, a primary side surface, and a secondary side surface, and an auxiliary portion positioned adjacent to the main portion and defining an auxiliary void. The auxiliary portion may be connected to the main portion at the secondary side surface. The auxiliary portion may include an auxiliary wall being spaced from the secondary side surface to define the auxiliary void therebetween, and at least one bridging web extending across the auxiliary void and connecting the auxiliary wall to the main portion, the at least one bridging web being inset from the opposite ends of the unit, the at least one bridging web being integrally formed with the main portion and the auxiliary wall. The auxiliary void may extend from one end to another end of the unit and may extend from the top to the bottom of the unit.