Foam Blocks with Connection Channels for Modular Assembly
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Solution Overview
Problem
The construction of large, temporary sets and decorative features using Styrofoam blocks results in significant waste and high material costs, as well as challenges in reusing or recycling the foam, due to the need for carving and discarding large portions of foam blocks to achieve the desired structure.
Innovation Solution
The development of foam blocks with pre-formed connection channels that allow for secure assembly with other blocks, using securing members such as foam, plastic, or metal retainers, enabling the creation of larger structures with reduced waste and improved recyclability by allowing for disassembly and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large foam blocks are used to construct sets and decorative features, then the structural integrity and size of the structure are improved, but material waste and disposal costs increase significantly
Solution Approach 1:
The invention divides large foam blocks into smaller modular blocks with standardized connection channels. Each block is a discrete unit that can be assembled into larger structures, allowing only the necessary foam volume to be used while minimizing waste from carving and discarding unnecessary portions.
Solution Approach 2:
Multiple smaller foam blocks are merged together through connection channels and securing members to form large-scale structures. This combining approach achieves the same structural integrity as large monolithic blocks while using less total material and reducing waste.
2Adaptability or versatility
If large foam blocks are carved to create desired structures, then the structural complexity and adaptability are improved, but material costs and waste increase
Solution Approach 1:
The foam system is segmented into standardized modular blocks with uniform connection channels. These modules can be assembled in various configurations to create different structures, providing adaptability without requiring carving of large blocks and thus reducing material consumption.
Solution Approach 2:
The modular block system allows dynamic reconfiguration of structures by assembling and disassembling standardized units. This enables adaptability for different scenes and purposes while maintaining efficient material usage, as blocks can be reused in multiple configurations.
3Ease of operation
If foam blocks are assembled using connection channels and securing members, then the ease of assembly and disassembly is improved, but the device complexity increases
Solution Approach 1:
The connection channels are designed with universal dimensions and shapes that work with standardized securing members. This universal interface simplifies the assembly process across different block configurations while maintaining manageable system complexity through standardization.
Solution Approach 2:
Securing members act as intermediaries between foam blocks, providing a simple mechanical connection mechanism. This intermediary component enables easy assembly and disassembly while keeping the overall system complexity manageable through the use of straightforward fastening elements.
Data Source
AI summary
A method of forming a foam block capable of being securely assembled to a different foam block to create a structure that is larger than the foam block is described herein. The method includes the following features. The foam block is received. Channels are formed in at least one side of the foam block. At least some of the channels are formed to accept a securing member that restricts vertical and horizontal movement of the foam block when the foam block is secured to the different foam block.