Foldable Construction Blocks with Interlocking Gussets
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Solution Overview
Problem
Existing construction block assembly sets for children fail to provide an easy-to-use solution for assembling and disassembling structures like forts, houses, and castles without the need for securing devices like tape or glue.
Innovation Solution
A set of generally flat boxes that can be easily folded into cube, rectangle, or prism shapes and secured using clips, allowing for the creation of various structures without the need for additional securing devices, and can be easily converted between folded and assembled orientations for storage and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If construction blocks are designed to be easily folded and assembled by children, then ease of operation is improved, but structural stability may deteriorate
Solution Approach 1:
The patent introduces pre-formed gussets as intermediary components that mediate between the simple folded box structure and the requirement for structural stability. These gussets act as stabilizing elements that reinforce corners and joints without complicating the assembly process for children.
Solution Approach 2:
The gussets are pre-formed and pre-attached to the box components before the child begins assembly. This preliminary preparation of stabilizing elements ensures structural integrity is built-in from the start, eliminating the need for children to perform complex stabilization tasks during assembly.
2Ease of operation
If construction blocks require no additional securing devices like tape or glue, then ease of operation is improved, but manufacturing precision may worsen
Solution Approach 1:
The box design incorporates self-securing features where flaps and gussets interlock with each other through the folding and taping process. The structure serves its own securing function through the mechanical interlocking of its components, eliminating the need for external fasteners while maintaining assembly simplicity.
Solution Approach 2:
The patent merges the structural and securing functions into a single integrated design. The gussets serve both as structural reinforcement elements and as components that create mechanical interlocking joints, combining multiple functions into unified elements that simplify assembly.
3Ease of operation
If boxes are designed to convert easily between flat and cubical orientations, then ease of operation is improved, but device complexity may worsen
Solution Approach 1:
The box design is segmented into distinct components (sides, flaps, gussets) that can be independently folded and assembled. This segmentation allows the structure to be constructed from simple flat components into a three-dimensional form through sequential folding operations, maintaining simplicity while enabling transformation.
Solution Approach 2:
The box design incorporates dynamic folding mechanisms that allow the structure to transition between flat storage configuration and assembled cubical form. The flaps and gussets are designed to move through defined folding paths, enabling easy conversion between states without permanent deformation or complex mechanisms.
Data Source
AI summary
A construction blocks assembly set is provided. The construction block assembly set has a plurality of generally flat boxes which may be folded into generally cube, rectangle, prisms or other shaped boxes. The boxes may be easily folded and secured in the folded orientation (cube, prism, etc) without the need for tape or other securing devices. Openings on the boxes allow for a clip to be inserted into in order to secure multiple boxes together to form a fort, a house, a clubhouse, a storefront, a castle building or other structure.