Prefabricated Masonry Lintel With Provisional Reinforcement

Solution Overview

Problem

Masonry construction requires site-constructed lintels with code-required reinforcement and grout, which complicates transportation and installation due to environmental and logistical challenges, such as weather conditions and scaffolding needs.

Innovation Solution

A prefabricated masonry lintel with provisional reinforcement embedded in narrow slits, allowing transportation without grout or code-required reinforcement, which is then completed with permanent reinforcement at the build site.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If code-required reinforcement and grout are installed at the build site, then structural strength and code compliance are achieved, but construction time increases and weather conditions affect progress

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-installing provisional reinforcement in narrow slits during manufacturing at the fabrication site. This allows the lintel to be transported in a hollow form without code-required reinforcement and grout, eliminating weather-dependent curing time and accelerating construction progress while maintaining structural integrity through the provisional reinforcement system.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If lintels are transported with code-required reinforcement and grout, then structural integrity is maintained, but transportation complexity and cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidtransportation complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-installing provisional reinforcement in narrow slits during manufacturing at the fabrication site. This allows the lintel to be transported in a hollow form without code-required reinforcement and grout, eliminating weather-dependent curing time and accelerating construction progress while maintaining structural integrity through the provisional reinforcement system.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the reinforcement parameter from permanent code-required reinforcement to temporary provisional reinforcement that is sufficient for transportation and handling. The narrow slit configuration (no larger than one-quarter inch) optimizes the reinforcement parameters to provide necessary tensile strength during transport while minimizing material usage and complexity.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If provisional reinforcement is embedded in narrow slits, then transportation is simplified and construction speed increases, but manufacturing precision requirements increase

Engineering Contradiction:

Improveconstruction speedVSAvoidslit formation precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent specifies precise parameter controls for the narrow slits (no larger than one-quarter inch width) to balance manufacturing precision requirements with construction productivity benefits. The slit dimensions are optimized to provide sufficient tensile strength for transportation while minimizing the complexity of formation processes.

Inventive Principle:

Principle #35Parameter changes

4Weight of moving object

If the lintel is transported hollow without grout, then transportation efficiency improves and site damage reduces, but tensile strength during transport must be provided by alternative means

Engineering Contradiction:

Improvetransportation weightVSAvoidtensile strength during transport

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent changes the reinforcement parameter from permanent code-required reinforcement to temporary provisional reinforcement that is sufficient for transportation and handling. The narrow slit configuration (no larger than one-quarter inch) optimizes the reinforcement parameters to provide necessary tensile strength during transport while minimizing material usage and complexity.

Inventive Principle:

Principle #35Parameter changes

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

This method simplifies transportation and installation by providing structural support during handling and lifting, reduces site damage, and allows for faster construction regardless of weather conditions, while ensuring compliance with building codes.

Implementation Method 1

Provisional reinforcement is fully embedded within the slit with a bonding material different from the mortar

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10544583B2Prefabricated masonry walls

Publication Date: 2020.01.28 CONSTRUCTIVE LLC

AI summary

A hollow prefabricated masonry wall panel is made at a fabrication site and is configured for transportation to a build site. The hollow prefabricated wall panel has a base row and an upper row formed of hollow blocks. A slit is formed in the top of each of the two side walls of the hollow blocks of the base row and upper row, the slit having a width no larger than 20% a width of a side wall. Provisional reinforcement is provided within each slit with a bonding material, a size of the slit and the provisional reinforcement configured to provide tensile strength during transportation of the hollow prefabricated wall panel from the fabrication site to the build site. At least one mid-row is laid between the base row and upper row so the hollow cavities are aligned to preserve hollow wall cavities that can accept code required reinforcement once transported to the build site.