Pre-insulated Block with Interlocking Foam Core
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Solution Overview
Problem
Traditional concrete masonry walls provide structural support but lack insulation, requiring additional insulation materials and labor, and they are not energy efficient, nor do they provide a physical, thermal, moisture, vapor, air, and fire barrier.
Innovation Solution
The development of insulated blocks with exterior and interior siding joined by a closed cell foam core, which cures to form a strong bond without separate adhesives, and features protrusions and recessions for self-alignment and multi-laminar edges for interlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional concrete masonry walls are used, then structural support is provided, but insulation performance is lacking
Solution Approach 1:
The insulated block combines concrete siding (for structural strength) with a closed-cell foam core (for insulation), creating a composite material solution that simultaneously provides both structural support and thermal insulation in a single integrated component, eliminating the need for separate insulation materials and labor
2Strength
If traditional concrete masonry walls are used, then structural support is provided, but additional insulation materials and labor are required
Solution Approach 1:
The patent merges the structural concrete siding and insulating foam core into a single pre-assembled insulated block unit, eliminating the need for separate insulation materials and the labor required to install them separately, thereby reducing assembly complexity while maintaining structural integrity
3Strength
If insulated blocks with adhesive bonding are used, then strong bond is achieved, but separate adhesives are required
Solution Approach 1:
The closed-cell foam core is designed to self-adhere to the concrete siding through its inherent bonding properties, eliminating the need for separate adhesive materials. The foam core provides both structural bonding and insulation functions in one material, reducing the quantity of additional substances required
4Device complexity
If blocks without interlocking features are used, then simple design is maintained, but alignment precision is poor
Solution Approach 1:
The block is segmented with protrusions and recessions that create interlocking features, allowing blocks to self-align during assembly. This segmentation provides built-in alignment guidance that improves manufacturing precision without significantly complicating the overall design
5Strength
If traditional masonry construction is used, then structural walls are built, but comprehensive barriers are not provided
Solution Approach 1:
The insulated block creates multiple functional layers within a single component: the concrete siding provides structural integrity and fire resistance, while the closed-cell foam core provides thermal insulation, moisture barrier, vapor barrier, and air barrier properties, thereby achieving comprehensive barrier performance alongside structural strength
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
These insulated blocks offer a mortarless, energy-efficient assembly that provides comprehensive barriers against physical, thermal, moisture, vapor, air, and fire, while being easily assembled by laypersons and requiring less material and labor.
Implementation Method 1
a closed cell foam core, which cures to form a strong bond without separate adhesives
Implementation Method 2
insulated blocks with exterior and interior siding joined by a closed cell foam core
Data Source
AI summary
An insulated block includes two sides and a self-adhering foam core joined to the two sides during the curing of the foam core. The foam core includes protrusions and recessions to facilitate joining of each insulated block with another insulated block. The insulated block is configured to be joined to other insulated blocks to create a structure or foundation which does not require mortar.