Corrugated Cardboard Blocks With Rigid Inserts for Load Bearing
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Solution Overview
Problem
Existing corrugated cardboard blocks lack sufficient structural strength and stability, limiting their utility in constructing durable and load-bearing structures, especially when used by children or adults.
Innovation Solution
The blocks are designed with base inserts made of stiffer materials, such as five-layer corrugated cardboard, and include foundation inserts for additional support, along with protrusions and overlays to enhance structural integrity and resistance to static and dynamic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blocks are made from corrugated cardboard blanks with simple bending and insertion, then ease of manufacture and self-assembly is improved, but structural strength and resistance to loads deteriorates
Solution Approach 1:
The patent combines cardboard body material with rigid base inserts made of five-layer corrugated cardboard or other stiff materials. This composite construction allows the block body to remain easy to manufacture while the base inserts provide the necessary structural strength and load-bearing capacity.
Solution Approach 2:
The block is divided into distinct segments: the cardboard body and the separate rigid base insert. This segmentation allows each component to be optimized independently - the body for ease of manufacture and the base insert for strength - while still forming an integrated unit through the insertion mechanism.
2Strength
If base inserts made of stiffer material are embedded in block bodies, then resistance to static loads is improved, but device complexity increases
Solution Approach 1:
The rigid base insert is nested within the cardboard block body, with the insert fitting into a cavity or recess in the block. This nesting approach integrates the complex strengthening element within the simpler outer structure, minimizing overall complexity while maintaining load-bearing capacity.
Solution Approach 2:
The rigid base insert is placed only at the base of the block where load-bearing capacity is most needed, rather than making the entire block complex. This localized application of stiffness provides maximum structural benefit with minimum added complexity.
3Reliability
If foundation inserts are added for lower blocks to transfer weight to ground, then reliability and stability of load-bearing structures is improved, but ease of operation deteriorates
Solution Approach 1:
The foundation insert is pre-integrated into the block design as a standard component, rather than requiring separate assembly steps. This preliminary integration maintains ease of operation by keeping the assembly process simple while ensuring reliable weight transfer to the ground for load-bearing structures.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~2a
AI summary
A set of blocks formed by bending blanks on the dividing lines of creasing, perforation, bigoperforation or notching, characterized in that it contains blocks (3, 7) consisting of a body (1, 5) and at least one insert (2, 6, 4, 8) located inside the body (1, 5), having side slots (13. 1) along the entire length of the sections connecting the side walls (1.2, 1.3, 5.2) of the formed body (1, 5), and having a bottom slot (13.2) along the length of the sections surrounding the horizontally located center wall (2.1, 6.1) of the basic insert (2, 6) located inside the body (1, 5), wherein side walls (2.2, 6.2) locate almost vertically above its center wall (2.1, 6.1).