Structural Block With Insulation Insert and Slotted Web
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Solution Overview
Problem
Commercially available 24-inch concrete blocks lack thermal insulation characteristics, leading to increased material and labor costs when external insulation is applied, and moisture issues with internal insulation, while also compromising structural strength.
Innovation Solution
A 24″×8″×12″ structural block with a high-density insulation material installed on the forward member, featuring a web with a slot to maximize R-values, and an insulation insert dividing the chamber into compartments to enhance thermal resistance without compromising load-carrying properties, conforming to NCMA standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If insulation is applied over the inside face of the block wall, then thermal insulation is achieved, but material and labor expense increases considerably and appearance problems occur
Solution Approach 1:
The patent combines the structural block and insulation material into a single integrated unit. The insulation insert is placed within the chamber of the block during manufacturing, merging two separate components (block and insulation) into one pre-assembled unit. This eliminates the need for separate insulation installation steps, reducing both material and labor expenses while maintaining thermal insulation performance.
Solution Approach 2:
The insulation material is pre-installed within the block chamber during the block manufacturing process rather than being installed later on-site. This preliminary action allows insulation to be integrated into the block structure before the block is used in wall construction, significantly reducing on-site labor time and expense while ensuring proper installation.
2Temperature
If insulation is applied over the inside face of the block wall, then thermal insulation is achieved, but appearance problems occur
Solution Approach 1:
By integrating the insulation insert within the block's internal chamber, the patent eliminates the need for external insulation layers that would protrude from or alter the block's external surfaces. The insulation is hidden inside the block structure, preserving the clean, uniform appearance of the block wall while still providing effective thermal insulation.
3Strength
If commercially available 24-inch blocks are used without internal insulation, then structural strength is maintained, but thermal insulation is insufficient leading to increased material and labor costs
Solution Approach 1:
The patent merges the structural block with an integrated insulation insert, creating a single component that provides both structural support and thermal insulation. This eliminates the need to use additional insulation materials and labor separately, reducing overall project costs while maintaining the block's structural strength for load-bearing applications.
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 effective thermal insulation, meets R-value requirements, and maintains structural integrity, allowing for faster construction with fewer blocks, competing with pre-fabricated materials while adhering to ASTM code requirements.
Implementation Method 1
a high-density insulation material having a density of about 1.3-1.8 lbs/ft3 installed on a forward member of the structural block... The insulation material allows the structural block to meet maximum R-values (insulated units must exhibit a specified minimum insulation R-value, which relates to a measure of thermal resistance (i.e., resistance to heat flow))
Data Source
AI summary
A structural block assembly for providing insulation to a structure comprising a structural block and an insulation insert. The structural block includes a body having oppositely situated forward and rearward members, oppositely situated proximal and distal members, and a chamber formed between the forward and rearward members and the proximal and distal members. A web, which is positioned within the chamber, centrally extends from the rearward member towards the forward member, wherein a gap is formed between the web and the forward member. The insulation insert is disposed between the web and the forward member, thereby dividing the chamber into a proximal-oriented compartment and a distal-oriented compartment. The web also has a slot formed therethough, wherein the slot assists in maximizing an R-value for the completed wall constructed with the block.