Vacuum-Sealed Plant Fiber Building Blocks for Construction

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Solution Overview

Problem

Conventional natural fibrous bales used in construction are labor-intensive, costly, prone to fire, pest infestation, moisture penetration, and thermal issues due to gaps, and limit design flexibility and material choices for coating.

Innovation Solution

A building block system comprising a rigid housing with interlocking mechanisms and vacuum-sealed plant fibers, allowing for efficient stacking and integration of electrical and plumbing conduits, providing improved insulation, fire resistance, and reduced moisture entry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional natural fibrous bales are used for construction, then the construction is inexpensive and provides good insulation, but the labor intensity and cost increase, and the risk of fire and pest infestation increases

Engineering Contradiction:

Improvefire resistanceVSAvoidconstruction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines natural fibrous materials (straw, hemp, corn stover) with a rigid housing structure and sealing mechanisms to create a composite building block system. This composite approach maintains the insulating properties of natural fibers while adding fire resistance through the housing structure and sealing, resolving the contradiction between affordability and fire safety

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies vacuum sealing to change the physical state of the plant fibers from loose to compressed, and from atmospheric exposure to sealed containment. This parameter change reduces moisture absorption, prevents pest infestation, and improves fire resistance while maintaining the natural insulating properties of the fibers

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional bales are stacked to construct structures, then the construction is simple and inexpensive, but gaps between bales create thermal breakpoints and moisture penetration

Engineering Contradiction:

Improvethermal insulationVSAvoidblock structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses flexible sealing elements and thin film barriers within the housing structure to eliminate gaps between blocks. The sealing mechanisms create a continuous thermal and moisture barrier while maintaining the simplicity of the overall block stacking construction method

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent merges the insulation function with the structural housing by integrating the plant fibers directly into the sealed chamber. This combination eliminates the need for separate insulation layers and ensures continuous thermal performance without gaps, while the housing structure provides both structural support and sealing

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If conventional bales are used, then the construction is straightforward, but the lack of studs limits hanging elements and design flexibility

Engineering Contradiction:

Improvedesign flexibilityVSAvoidconstruction simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent designs the housing structure to serve multiple functions: structural support, sealing, and integration of utilities. The standardized housing with integrated conduits and sealing mechanisms provides a universal platform that accommodates various designs and hanging elements while maintaining construction simplicity through modular assembly

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If plaster is used to coat conventional bales, then the coating provides protection, but the plaster degrades leading to water and pest penetration

Engineering Contradiction:

Improvemoisture resistanceVSAvoidcoating durability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the traditional plaster coating with a durable sealed housing structure that provides long-term protection. The sealed chamber design eliminates the need for degradable surface coatings by providing inherent moisture and pest resistance through the housing and sealing mechanisms themselves

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 results in a durable, load-bearing, and eco-friendly construction system with reduced labor and material costs, improved thermal insulation, and enhanced fire and pest resistance, offering design flexibility and reduced construction time.

Implementation Method 1

a vacuum fitting secured to the housing and adapted to enable air to be drawn out of the chamber

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

improved thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11643806B2Building blocks containing plant fibers, construction system using same, and method of construction using same

Publication Date: 2023.05.09 BERGER ERIC

AI summary

A building block comprises a rigid housing defining a chamber and plant fibers contained within the chamber. A construction system comprises a plurality of such building blocks, selectively stackable to form a wall. A method of construction comprises obtaining a plurality of such building blocks, inserting plant fibers into the chamber, and stacking the plurality of building blocks to form one or more walls.