Modular Construction Blocks with Tenon Joints for Wall Assembly

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Solution Overview

Problem

Existing construction methods using structural insulated panels (SIPs) face challenges in quick and versatile assembly of wall structures, as they often require complex connections and external fitting means, which can complicate the process and increase weight due to solid construction blocks.

Innovation Solution

The design of modular construction blocks featuring hollow support members with transverse openings for tenon elements and a frame arrangement with external segments within panels, allowing for versatile assembly and reduced weight through internal cavities, along with securing pins and slots for stability, enables efficient and lightweight wall construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid construction blocks are used, then structural strength is improved, but weight increases and assembly complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidblock weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The construction block is divided into multiple support members (first support member, second support member, etc.) that are connected through a frame arrangement. Each support member can be separate and connected via tenon elements, allowing the structure to achieve strength through distributed support rather than a solid monolithic form, thereby reducing overall weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support members contain hollows (first hollow, second hollow) that are filled with insulating material. This creates a porous or cavity-based structure that maintains structural integrity while significantly reducing the weight of the block compared to a solid construction, achieving the strength-weight trade-off.

Inventive Principle:

Principle #31Porous materials

2Stability of the object's composition

If complex connection methods are used, then assembly stability is improved, but assembly time increases

Engineering Contradiction:

Improveassembly stabilityVSAvoidassembly time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The support members are pre-formed with integrated tenon elements and hollows during manufacturing. The frame arrangement is pre-assembled with support members attached in specific orientations. This preliminary preparation allows for rapid on-site assembly where blocks are simply connected through pre-configured tenon interfaces without requiring complex field construction, thus reducing assembly time while maintaining stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The tenon elements are designed to automatically align and connect support members through the hollows without requiring additional fasteners or complex connection procedures. The interlocking mechanism of tenons fitting into hollows provides self-aligning and self-securing connections that maintain stability while enabling quick assembly operations.

Inventive Principle:

Principle #25Self-service

3Reliability

If external fitting means are used, then connection reliability is improved, but device complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tenon elements are integrated directly into the support members as built-in connection features rather than separate external components. The hollows are formed as part of the support member structure itself. This merging of connection features into the main structure eliminates the need for separate external fitting means, reducing overall device complexity while maintaining reliable connections through the integrated tenon-hollow interfaces.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If modular assembly is used, then assembly speed is improved, but structural complexity increases

Engineering Contradiction:

Improveassembly speedVSAvoidstructural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The support members are designed with universal interfaces that can connect in multiple orientations and configurations. The tenon elements and hollows are standardized across different support members, allowing the same basic module to be assembled in various arrangements to create different wall configurations. This universality enables rapid modular assembly without requiring specialized components for each configuration, achieving speed without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10358819B2Construction block, a wall structure comprising the same, and a method for manufacture of said construction block and of said wall structure

Publication Date: 2019.07.23 TANAMI YONATHAN

AI summary

A construction block comprising: two or more support members each of which has a first face and a second face opposite the first face and comprises a hollow between the first and second faces, said hollow having openings facing in a direction transverse to a direction normal to the first and second faces, said opening configured for receiving at least a portion of a tenon element allowing two such construction blocks to be assembled; a frame arrangement connecting the support members to each other, said frame arrangement having external segment(s) extending from at least one of the first and second faces in a direction away from the hollow; a first panel conterminous with the first faces; and a second panel conterminous with the second faces; wherein at least a portion of the external segment of the frame arrangement is contained within one of the first and second panels.