Block System With Interlocking Connective Protrusions
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Solution Overview
Problem
Blocks used as toys or for construction often shift, rotate, or stray from their desired arrangement due to lack of coupling mechanisms, leading to instability in stacking and arrangement.
Innovation Solution
A block system featuring connective protrusions on each side, including middle and lateral connective protrusions, which allow blocks to couple securely by engaging with corresponding protrusions on adjacent blocks, creating a stable structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If blocks are stacked or disposed next to one another without coupling mechanisms, then the blocks are simple to manufacture and use, but the blocks shift, rotate, or stray from their desired arrangement
Solution Approach 1:
The block is divided into distinct functional segments: a base portion and a connective protrusion. The connective protrusion is further segmented into a middle base portion and a middle overhang portion, allowing independent optimization of each segment's function while maintaining overall block stability.
Solution Approach 2:
The middle overhang portion is nested within the overhang space of an adjacent block, creating a interlocking relationship. This nesting mechanism allows the protrusion of one block to fit into the recess of another, preventing shifting and rotation while maintaining structural stability.
2Reliability
If connective protrusions are added to blocks to prevent shifting and rotation, then the stability of block arrangement is improved, but the complexity of block structure increases
Solution Approach 1:
The connective protrusion features local quality variations with different portions serving specific functions: the middle base portion provides structural support and alignment, while the middle overhang portion extends into the adjacent block's overhang space to prevent lateral shifting and rotation. Each portion is optimized for its specific coupling function.
Solution Approach 2:
The middle overhang portion extends in a direction substantially perpendicular to the base surface, adding a vertical dimension to the coupling mechanism. This dimensional extension allows the protrusion to engage with the overhang space of an adjacent block, creating multi-dimensional constraints that prevent shifting and rotation.
3Reliability
If middle and lateral connective protrusions are used to couple blocks securely, then the reliability of block coupling is improved, but the manufacturing complexity increases
Solution Approach 1:
The middle base portion and middle overhang portion are merged into a single integral connective protrusion structure, eliminating the need for separate assembly steps. This unified structure can be manufactured as one piece using conventional molding or machining processes, reducing manufacturing complexity while maintaining the dual-function coupling mechanism.
Solution Approach 2:
The connective protrusion design is universal and can be applied to all blocks in the system, allowing identical manufacturing processes for all blocks. The same protrusion structure serves multiple functions: providing structural support, preventing lateral shifting, and preventing rotation, thereby simplifying manufacturing while achieving reliable coupling.
Data Source
AI summary
A block may comprise a base comprising a first block side comprising a first side plane and a connective protrusion coupled to the base and extending distally outwardly and substantially perpendicularly from the first side plane. The connective protrusion may comprise a center pillar coupled to the base extending distally outward from the first side plane, a base portion coupled to the center pillar and the base and extending axially and substantially perpendicularly from the center pillar in a first direction, and an overhang portion coupled to the center pillar extending axially and substantially perpendicularly from the center pillar in a second direction opposite the first direction such that there is an overhang space between the first side plane and the overhang portion. The block may further comprise additional connective protrusions, and the connective protrusions of multiple blocks may enable the coupling of such blocks.