Mortarless Wall Assembly with Movable Trellis Connectors
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Solution Overview
Problem
Existing mortarless freestanding wall assemblies face challenges with instability and difficulty in assembly, leading to buckling, leaning, and toppling due to lack of mortar, requiring skilled labor and significant time for reassembly when issues arise.
Innovation Solution
A wall assembly utilizing a trellis panel with movable connectors that allow relative movement and rotation of blocks, providing a rigid structure and enabling the use of thinner blocks, which can be easily handled and installed, and allowing for varied orientations and patterns, including the incorporation of different materials and designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mortarless stacked blocks are used, then ease of assembly is improved, but stability and reliability deteriorate due to buckling, leaning, and toppling
Solution Approach 1:
The patent introduces a connector as an intermediary element between the blocks and the reinforcing structure. The connector includes a first end that engages with the block and a second end that engages with the reinforcing structure, mediating the connection and allowing for stable mortarless assembly without direct block-to-block dependency
Solution Approach 2:
The wall assembly is segmented into distinct functional components: blocks for facing, a reinforcing structure (trellis) for structural integrity, and connectors for joining. This segmentation allows each component to perform its specific function optimally - blocks provide aesthetic finish while the reinforcing structure provides stability
2Weight of moving object
If thin facing panels are used, then weight and ease of handling are improved, but stability and ease of installation deteriorate due to inherent instability
Solution Approach 1:
The connector serves as a mediator that attaches thin facing panels to the reinforcing structure, providing the necessary support for installation without requiring heavy blocks. The connector compensates for the inherent instability of thin panels during installation
Solution Approach 2:
The patent uses thin facing panels that copy the aesthetic appearance of traditional thick stone blocks while being much lighter. The structural function is copied from the block itself to a separate reinforcing structure, allowing the facing panels to be optimized for weight and appearance
3Length of stationary object
If back to back assembly is used, then wall width requirement is met, but assembly difficulty increases due to alignment requirements of rows and retaining grooves
Solution Approach 1:
The reinforcing structure acts as a common intermediary framework to which blocks on both sides are attached. This eliminates the need for direct back-to-back alignment of retaining grooves, as both sides independently connect to the central trellis structure
Solution Approach 2:
The wall is segmented into independent facing layers attached to a central reinforcing skeleton. This segmentation allows each facing layer to be assembled independently without requiring precise alignment with the opposite layer, simplifying the back-to-back assembly process
4Reliability
If conventional stacked blocks are used, then structural stability is maintained, but material cost and skilled labor requirement increase
Solution Approach 1:
The patent copies the structural stability function from traditional thick blocks to a separate reinforcing structure (trellis). This allows the use of thinner, less expensive blocks for the facing while the trellis provides the necessary structural support, reducing material costs
Solution Approach 2:
The connector design allows for controlled movement and adjustment during assembly, accommodating settling and base changes dynamically. This maintains structural stability over time while using lighter, less expensive materials compared to rigid conventional block assemblies
Data Source
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AI summary
Disclosed is a wall assembly including preformed building blocks and a trellis type support member for maintaining the building blocks in place in the desired orientation. The wall assembly further includes at least one support for holding the trellis upright. The individual blocks are connected to the supporting trellis for added stability. Although not every block in the wall need be connected to the trellis support member in order to achieve the desired added stability, it is preferred to connect each block in the wall to the trellis. Connectors are provided for connecting the blocks to the trellis. Each block preferably is connected to the trellis by at least one connector, most preferably by a pair of connectors. To accommodate relative movement or shifting of the blocks during installation and in situ, the connectors are preferably movably connected to the trellis or the block, or both. Although this allows the blocks to shift relative to one another and relative to the trellis, buckling, leaning and toppling of the wall is avoided, since the combination of the blocks with the trellis panel and the support results in an overall rigid structure and the trellis panel and support maintain the structure in the desired upright orientation.