Modular Plastic Building Blocks with Mortise and Tenon Joints

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Solution Overview

Problem

Conventional wooden construction methods are inefficient, requiring multiple builders and being time-consuming, environmentally harmful due to deforestation and resource-intensive, and costly due to fluctuating lumber prices.

Innovation Solution

Modular prefabricated building blocks made from recycled plastic, featuring mortise and tenon joints for easy assembly and weight-bearing capabilities, allowing single-person construction and various configurations, reducing environmental impact and construction time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional wooden construction methods are used, then structural strength and stability are achieved, but construction time and labor requirements increase significantly

Engineering Contradiction:

Improveconstruction speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The building structure is divided into modular blocks that can be pre-fabricated and then quickly assembled on-site. Each block contains integrated framing and sheathing, allowing parallel production and reducing on-site assembly time from days to hours.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Building blocks are pre-assembled with frames and sheathing attached before delivery to the construction site. This preliminary preparation allows complex structural elements to be manufactured off-site while simplifying on-site construction to basic assembly operations.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional wooden construction methods are used, then structural integrity is maintained, but environmental harm increases due to deforestation and resource consumption

Engineering Contradiction:

Improvestructural integrityVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The material composition is changed from natural wood to recycled plastic, fundamentally altering the environmental impact profile while maintaining structural performance. This parameter change enables the structure to resist rot, termites, and moisture without requiring additional chemical treatments.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The building blocks utilize composite construction combining recycled plastic materials to replace traditional wood-based products. This composite approach maintains structural integrity while eliminating the need for deforestation and reducing vulnerability to biological degradation.

Inventive Principle:

Principle #40Composite materials

3Productivity

If prefabricated walls are used, then construction time is reduced, but weight increases requiring multiple skilled builders

Engineering Contradiction:

Improveassembly efficiencyVSAvoidblock weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

Large prefabricated walls are segmented into smaller modular blocks that can be individually handled and assembled. This segmentation reduces the weight and size requirements for lifting equipment while maintaining the overall structural performance through proper joint design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized block designs allow for replication of successful lightweight configurations. Once an optimal block weight and dimension is developed, it can be copied across multiple building projects, achieving both lightweight construction and assembly efficiency.

Inventive Principle:

Principle #26Copying

4Ease of manufacture

If wooden construction materials are used, then traditional building methods are maintained, but cost increases due to fluctuating lumber prices

Engineering Contradiction:

Improveconstruction simplicityVSAvoidmaterial cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The material basis is changed from commodity-dependent wood to recycled plastic with more stable pricing. This parameter change decouples construction costs from volatile lumber markets while maintaining manufacturing simplicity through standardized block production processes.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10415240B2Modular prefabricated building blocks

Publication Date: 2019.09.17 WAWI AMGAD

AI summary

A building block for a modular system for construction of a wall frame, the building block having a frame portion having: a rear exterior side; a front interior side; a top end; a bottom end; a left side; and a right side; a sheathing extending across the rear exterior side; at least a first dowel protrusion or at least a first dowel cutout; at least a first mortise; and at least a first tenon opposite to the at least a first mortise; such that the at a first mortise is capable of associating with a corresponding first tenon of a second building block to create a first mortise and tenon joint; and such that the at least a first tenon is capable of associating with a corresponding first mortise of a third building block to create a second mortise and tenon joint.