Masonry Block With Polygonal Insulating Cavity
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Solution Overview
Problem
Current brick manufacturing methods fail to efficiently combine high thermal and sound insulation with stability and cost-effectiveness, particularly in masonry applications, where existing solutions often require labor-intensive pre-cutting of insulating materials and may not adequately address resonance issues.
Innovation Solution
A brick design featuring a polygonal insulating material body with vertically arranged cavities, filled with pourable foam-like or granular materials, which harden in place, and lateral receptacles for additional insulation, allowing for efficient production and improved sound and thermal insulation while maintaining stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pre-cut insulating material is pushed into cavities with friction fit, then thermal insulation is improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The insulating material is changed from pre-cut solid form to pourable liquid/semi-liquid form that hardens in place. This parameter change eliminates the need for pre-cutting operations and friction fit insertion, reducing manufacturing complexity while maintaining thermal insulation performance through complete cavity filling.
Solution Approach 2:
The patent uses pourable insulating material that can be injected or poured into cavities through nozzle arrangements, enabling automated filling operations. This hydraulic/pneumatic approach replaces manual friction fit insertion, reducing labor intensity and manufacturing complexity.
2Ease of manufacture
If conventional brick design is used, then production is simple, but sound insulation and heat insulation are insufficient
Solution Approach 1:
The brick is segmented to include multiple vertically arranged cavities with polygonal cross-sections instead of a solid structure. This segmentation creates air gaps that reduce sound transmission while the pourable insulation material fills these segments to provide additional thermal and acoustic insulation, maintaining production simplicity through standardized cavity formation.
Solution Approach 2:
The brick combines traditional brick material with pourable insulating material (such as mineral foam or granular materials with binders) to create a composite structure. This composite approach enhances sound and heat insulation properties while the vertical cavity design maintains ease of manufacture through automated filling processes.
3Ease of manufacture
If conventional brick design is used, then production is simple, but heat insulation is insufficient
Solution Approach 1:
The insulating material is changed from pre-cut solid form to pourable liquid/semi-liquid form that hardens in place. This parameter change eliminates the need for pre-cutting operations and friction fit insertion, reducing manufacturing complexity while maintaining thermal insulation performance through complete cavity filling.
4Object-affected harmful factors
If polygonal insulating material body is used, then sound insulation is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of inserting pre-formed polygonal insulating blocks into cavities (complex approach), the patent inverts the process by forming polygonal cavities in the brick and then pouring liquid/semi-liquid insulating material into them. The material takes the polygonal shape itself, eliminating the need for complex pre-cutting and insertion operations while maintaining the sound insulation benefits of the polygonal structure.
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
The design enhances soundproofing and heat-insulating properties, reduces production costs, and allows for automated filling processes, ensuring consistent material flow and reduced resonance, while maintaining structural integrity.
Implementation Method 1
The insulating material body preferably comprises a foam-like insulating material which can be filled into a cavity of the brick in a pourable, in particular liquid or semi-liquid, state. This fills the corners well and allows the insulating material to dry or harden, while remaining elastic.
Implementation Method 2
The polygonal structure of the body of insulating material improves the acoustic properties of the brick and thus of the wall built from these bricks, since the longitudinal sound conduction is reduced.
Implementation Method 3
The polygonal design of the cavity or of the brick walls forming it further improves the effect of reduced longitudinal sound conduction, since the structure has a stiffening effect and the wall is therefore less prone to resonance effects.
Data Source
Figure 1
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AI summary
A masonry block (1) with a masonry block interior (4) enclosed by outer masonry walls (2), wherein at least one of the outer masonry walls (2) is designed as a joining surface (7) for lateral connection with further masonry blocks (1). The masonry block (1) further comprises at least one insulating material body (9) arranged vertically within the masonry block interior (4), wherein the insulating material body (9) has a polygonal cross-section, in particular with three, five or more cross-sectional corners (12).