Variable Retaining Wall Blocks with Removable Setback Knobs
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Solution Overview
Problem
Current retaining wall systems require multiple inventory levels for different setback degrees, leading to increased costs and labor due to the need for double-faced stones and complex packaging, as they can only accommodate a single setback degree, which limits flexibility and efficiency in installation and transportation.
Innovation Solution
A variable retaining wall system featuring blocks with hollow cores and removable setback knobs of different angles, allowing for multiple setback positions from a single-sided stone, reducing the need for additional inventory and simplifying packaging and installation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple setback degrees are accommodated using different stones, then the correct setback can be achieved, but additional product inventory is required increasing costs and storage requirements
Solution Approach 1:
A single stone design incorporates multiple setback degrees through integrated knobs of different diameters (first knob with diameter D1 for first setback degree, second knob with diameter D2 for second setback degree). This universal design allows one stone type to serve multiple setback functions, eliminating the need for separate inventory for each setback degree while maintaining adaptability to different wall configuration requirements
Solution Approach 2:
Multiple setback functionality is merged into a single stone by combining knobs of different diameters on the same stone. The first knob and second knob are both integrated into the stone structure, allowing the installer to select the appropriate knob for the desired setback degree without requiring separate stone types for each setback option
2Adaptability or versatility
If knobs are removed to change setback degree, then setback adjustment is possible, but the knob breaks above the surface affecting height and requiring additional labor
Solution Approach 1:
Break-off recesses are pre-formed in the stone at locations below the top surface, positioned to receive the knobs when broken. This preliminary preparation ensures that when knobs are removed for setback adjustment, they break cleanly at the recess location rather than above the surface, preventing height variation and eliminating the need for subsequent cleaning or grinding operations
Solution Approach 2:
The break-off recesses are molded into the stone during manufacturing, creating a precise negative space that matches the knob geometry. This ensures clean breakage at the correct location and provides a smooth transition surface that eliminates the need for additional finishing work after knob removal
3Adaptability or versatility
If double-faced stones are used to provide multiple setback options, then versatility is improved, but manufacturing cost increases
Solution Approach 1:
Single-faced stones are designed with multi-functionality by incorporating knobs of different diameters (first knob with diameter D1, second knob with diameter D2) on the same stone. This eliminates the need for expensive double-faced stone manufacturing while providing the same versatility for multiple setback degrees, reducing material and manufacturing costs
4Reliability
If machines are used to turn stones over for interlocking knobs during packaging, then proper interlocking is achieved, but packaging complexity and equipment requirements increase
Solution Approach 1:
The stone is designed to be packaged with the knobs facing upward rather than requiring the stone to be turned over during packaging. The core area of the stone is positioned to receive knobs from stones below, and the packaging process simply places stones with knobs facing up, eliminating the need for complex machinery to turn stones over while ensuring proper interlocking
Data Source
AI summary
A variable retaining wall system may include a block having a top, a bottom, and a hollow core area. At least one set of setback knobs may attach to the block. The at least one set of setback knobs may include a primary set of setback knobs and a secondary set of setback knobs of a different angle than the primary set of setback knobs. The at least one set of setback knobs may be removable.