Tensioned Cable Wall Assembly for Mortar-Free Block Installation
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Solution Overview
Problem
Conventional construction methods require skilled labor and mortar, leading to costly and potentially flawed installations, especially in thin material applications like exposed brick façades or insulation, where quality and regulatory compliance are challenging due to issues like surface flatness and material detachment.
Innovation Solution
A constructive assembly using tensioned cables and prismatic blocks that eliminate the need for mortar, allowing for easy, high-quality wall construction with a defect-free finish, where cables are fixed between bearing members and blocks are anchored to the cables, ensuring stability and preventing material detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional construction methods using mortar are employed, then walls can be built with traditional materials, but the installation requires skilled labor and is time-consuming and costly
Solution Approach 1:
The patent replaces the traditional mortar-based mechanical bonding system with a cable-tension suspension system. Cables are anchored to the ceiling and pass through recesses in the blocks, suspending the wall structure without requiring mortar application or skilled masonry work, thereby eliminating the need for skilled labor while maintaining structural integrity
Solution Approach 2:
The wall construction is segmented into discrete blocks that can be independently positioned and assembled. Each block features standardized recesses for cable attachment, allowing modular installation without requiring continuous mortar work, thus speeding up the installation process while maintaining quality
2Manufacturing precision
If conventional construction methods are used, then traditional wall building is possible, but the finish quality is compromised due to lack of flatness and presence of stains
Solution Approach 1:
The blocks are pre-manufactured with precisely engineered recesses positioned at exact locations and orientations. This preliminary preparation ensures that when the blocks are assembled using the cable suspension system, the wall surface achieves uniform flatness and alignment without requiring post-installation adjustments or skilled finishing work
Solution Approach 2:
The invention changes the fundamental parameter of wall attachment from chemical bonding (mortar) to mechanical suspension (cables). This parameter change enables precise control over block positioning and surface alignment, achieving high manufacturing precision in surface flatness while the modular nature of the system keeps the construction process manageable
3Reliability
If thin materials like tiles are used in conventional construction, then aesthetic finishes are possible, but the materials risk becoming detached
Solution Approach 1:
The patent replaces weak chemical bonding of thin materials with strong mechanical suspension through cables. The cable system passes through recesses in the blocks and is anchored to the ceiling structure, creating a robust mechanical attachment that reliably holds thin materials like tiles without the risk of detachment that plagues conventional mortar applications
Solution Approach 2:
The cable suspension system acts as a counterweight mechanism, with the tension in the cables balancing the weight of the thin materials. This anti-weight approach ensures that thin materials like tiles are securely held in place by the tensile strength of the cables rather than relying on the bonding strength of mortar, significantly improving attachment reliability
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 enables faster, cleaner, and more cost-effective construction of walls with improved quality and compliance, reducing the risk of material detachment and ensuring high-quality finishes without skilled labor, while accommodating varying wall geometries and regulatory demands for sound and thermal insulation.
Implementation Method 1
a plurality of cables intended for being arranged under stress in the vertical position
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3D
AI summary
The present invention relates to a constructive assembly for building walls which allow forming wall coverings. Examples of coverings that can be formed with the present invention are façades, party walls and partition walls. The constructive assembly is characterized by being formed by a plurality of cables intended for being arranged under stress in the vertical position, and a plurality of blocks having coupling means for coupling them to cables such that integral joining is assured, forming the wall. Walls thus formed do not require the use of mortar or the need to be built by skilled labor, making it possible to build reformed or new exposed wall faces more easily and in a cleaner and faster manner and, in the case of thin material (tiles), with the certainty that such material will not become detached.