Self-Locking Prefabricated Blocks with Steel Fiber Reinforcement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing prefabricated construction solutions lack sufficient firmness, stability, and resistance without the use of mortar mixtures or structural supports, and fail to achieve suitable finishes for openings and 90-degree angles in wall connections.

Innovation Solution

Prefabricated blocks made of Portland cement mortar reinforced with steel fibers that interlock without external or internal structural support, adhesive, or mortar mixture, allowing for self-locking and free-standing structures with complementary blocks like lintel beams, head-blocks, and semi-blocks for constructing pillars, walls, and buildings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If prefabricated pieces are designed without mortar mixture or structural support, then construction simplicity is improved, but firmness and stability deteriorate

Engineering Contradiction:

Improveconstruction simplicityVSAvoidfirmness and stability

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The block combines Portland cement mortar with steel fibers to create a composite material that achieves both high strength (16 tons compression load) and construction simplicity. The steel fibers reinforce the cement mortar, eliminating the need for additional structural supports while maintaining firmness and stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The block is designed to be self-supporting through its internal structure with hollow cavities and protrusions that interlock automatically. The block serves its own structural support function without requiring external mortar mixtures or additional structural elements, achieving both simplicity and strength.

Inventive Principle:

Principle #25Self-service

2Strength

If traditional mortar mixture is used, then firmness is improved, but construction time and complexity increase

Engineering Contradiction:

ImprovefirmnessVSAvoidconstruction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The block incorporates its own binding and structural support functions within its design. The hollow cavities and protrusions create automatic interlocking between blocks, eliminating the need for separate mortar application steps and reducing construction time while maintaining firmness.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The structural support function and the binding function are merged into the block itself through the cement mortar matrix reinforced with steel fibers. This integration eliminates the need for separate mortar mixture application and reduces the number of construction steps.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If simple block design is used, then manufacturing ease is improved, but ability to form finishes and angles deteriorates

Engineering Contradiction:

Improveblock design simplicityVSAvoidfinish quality and angle formation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The block features asymmetric design elements including hollow cavities positioned at specific locations and protrusions with particular geometries. These asymmetric features enable precise interlocking and allow the formation of 90-degree angles and openings while maintaining ease of manufacture through standardized block production.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The block is segmented into functional zones: solid portions for structural strength, hollow cavities for interlocking and lightweighting, and protrusions for connection. This segmentation allows each element to be optimized for its specific function while maintaining overall manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

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

The solution provides stable, high-resistance structures that can support significant loads without additional support, enabling rapid construction with professional finishes and the ability to form 90-degree angles, while eliminating the need for plaster or mortar, thus enhancing construction efficiency and speed.

Implementation Method 1

The blocks are made of Portland cement mortar reinforced with steel fibers. The Portland cement mortar reinforced with the steel fibers provides the block with enough strength so that the wall, room, or building can be raised without the need of external or internal structural support

Methodology Applied

Scientific EffectFiber reinforcement:

Data Source

PatentUS9187895B2Self-locking block and complementary pieces for the raising of pillars and free-standing walls

Publication Date: 2015.11.17 RODRIGUEZ CARASSUS ALBERTO

AI summary

The disclosure concerns to rooms or buildings constructed by raising walls using prefabricated blocks made of Portland cement mortar reinforced with steel fibers. The prefabricated blocks are stable without requiring a mortar mixture, or any additional internal or external structural support for the construction of the walls.