Cardboard Knockdown Building Blocks with Interlocking Slots
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Solution Overview
Problem
There is a need for environmentally friendly knockdown building block sets that remain easy and fun to use, as traditional plastic toys contribute to environmental pollution and lack sustainability.
Innovation Solution
The development of an environmentally friendly knockdown building block set made from recycled cardboard, with adhesive-free manufacturing and the use of plant-based inks, along with integrating the shipping box as a component of the play set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional plastic building blocks are used, then durability and interlocking strength are improved, but environmental pollution and lack of sustainability worsen
Solution Approach 1:
The patent changes the material parameter from traditional plastic to corrugated cardboard, transforming the physical and chemical properties of the building blocks. This material substitution maintains structural integrity through the corrugated fluting design while eliminating the environmental harm associated with plastic waste and non-biodegradability.
Solution Approach 2:
The patent enables the building blocks to be easily disassembled and flattened for compact storage and disposal. The corrugated cardboard material can be readily recycled or composted, allowing the blocks to be discarded without environmental harm and potentially recovered through recycling programs.
2Object-generated harmful factors
If cardboard material is used instead of plastic, then environmental friendliness is improved, but structural strength and durability worsen
Solution Approach 1:
The patent applies different structural qualities to different parts of the cardboard block. The corrugated fluting provides localized strength in specific directions, while flat surfaces allow for printing and interlocking. This local differentiation of material properties enables the cardboard to achieve sufficient structural strength for building play while maintaining environmental friendliness.
Solution Approach 2:
The patent uses corrugated cardboard as a composite material structure, combining outer liners with fluting in a sandwich construction. This composite structure provides enhanced strength-to-weight ratio and structural integrity compared to solid cardboard, enabling the blocks to maintain durability while using environmentally friendly materials.
3Stability of the object's composition
If adhesive is used in manufacturing, then block integrity is improved, but manufacturing complexity and environmental impact worsen
Solution Approach 1:
The patent treats the cardboard blocks as disposable or short-lifecycle objects that do not require permanent adhesive bonding. The blocks are designed to be assembled and disassembled repeatedly without adhesives, using friction and interlocking geometry instead. This approach simplifies manufacturing by eliminating adhesive application steps while maintaining sufficient block integrity for their intended temporary use.
4Loss of substance
If shipping box is integrated as a component, then waste reduction is improved, but design complexity worsens
Solution Approach 1:
The patent designs the shipping box to serve multiple functions: it protects the blocks during transit, provides storage when not in use, and can be disassembled to create additional building components. This multi-functionality reduces waste by eliminating the need for separate storage containers while the modular design allows the box to be integrated without excessive complexity.
Solution Approach 2:
The patent merges the shipping box with the building block set by designing the box to be composed of the same corrugated cardboard material and to function as both packaging and play component. This consolidation eliminates the need for separate storage containers and reduces overall material waste, while the simple corrugated structure keeps the design relatively straightforward.
Data Source
AI summary
An environmentally friendly knockdown building block set includes a cardboard shipping box; a plurality of main cardboard blanks each configured to form a base block including four connecting slots therein as wide as the base block thickness; a plurality of coupling cardboard blanks each configured to form an H-block including two connecting slots therein with each slot located between two legs of the H-block and as wide as the H-block thickness; wherein the connecting slots of each base black and each H-block allow for receipt and interconnection of the base block or H-block with an associated base block or H-block forming a notched connection for the base blocks and H-blocks; wherein at least the main blocks include an inking pattern using plant based environmentally friendly inks; and wherein the shipping box is an integral component configured to be integrated into structures formed by the set.