Interlocking Polymer Base Assembly for Adaptable Site Installations
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Solution Overview
Problem
Existing base and support systems for architectural, landscape, and recreational installations face challenges in adaptability, durability, and efficiency, requiring extensive redesign, specialized tools, and increased labor and material waste, especially for complex installations.
Innovation Solution
A polymorphic interlocking and interchangeable system using expanded polymer units with lateral and vertical interlocking features, enabling seamless assembly across horizontal and vertical planes, with a protective polymer coating for durability and allowing rotational orientation in 90-degree increments, and field-modifiability for accommodating various components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing base and support systems are used for architectural, landscape, and recreational installations, then installations can be completed with traditional methods, but extensive redesign, specialized tools, and increased labor are required especially for complex installations
Solution Approach 1:
The polymer base body is designed with universal interlocking features (lateral interlocking features on vertical surfaces and vertical interlocking profiles on horizontal surfaces) that enable the same component to function in multiple orientations and configurations, accommodating architectural, landscape, and recreational applications without requiring redesign for different installation types
Solution Approach 2:
The system allows dynamic adaptation through rotational orientation of polymer base bodies in 90-degree increments and field-modifiability by cutting or machining, enabling the installation system to adjust to complex site conditions and design requirements without requiring specialized tools or extensive redesign
2Productivity
If traditional base systems are used, then installations can be completed with standard procedures, but installation time and labor intensity increase
Solution Approach 1:
The base system is divided into discrete polymer base bodies with standardized interlocking features, allowing rapid assembly through simple engagement of lateral and vertical interlocking features without requiring complex fastening procedures or specialized installation tools, thereby reducing installation time and labor intensity
Solution Approach 2:
The polymer base bodies are pre-formed with integrated interlocking features and protective coatings during manufacturing, eliminating the need for on-site preparation work and enabling direct assembly, which significantly reduces installation time compared to traditional base systems requiring现场 processing
3Loss of substance
If conventional base systems are used, then installations can be completed with traditional materials, but material waste increases
Solution Approach 1:
The modular polymer base bodies can be disassembled and reconfigured for different applications, allowing materials to be recovered and reused rather than discarded, reducing material waste while maintaining versatility across architectural, landscape, and recreational installations
Solution Approach 2:
The same polymer base body design with standardized interlocking features serves multiple installation types and configurations, eliminating the need for different specialized components for different applications, thereby reducing overall material consumption and waste
4Reliability
If existing support systems are used, then installations can be completed with standard components, but durability and seamless assembly across horizontal and vertical planes are compromised
Solution Approach 1:
The lateral interlocking features and vertical interlocking profiles are integrated into a unified polymer base body structure, ensuring seamless assembly across horizontal and vertical planes with consistent alignment and structural continuity, enhancing durability without requiring complex multi-component systems
Solution Approach 2:
The interlocking features are designed with complementary male and female profiles that provide uniform engagement characteristics across all connections, ensuring consistent alignment and structural integrity throughout the installation, simplifying the assembly process while maintaining high durability standards
Data Source
AI summary
A polymorphic interlocking and interchangeable base system for architectural, landscape, and recreational feature installations is disclosed. Embodiments include expanded polymer units with lateral and vertical interlocking features, enabling seamless assembly in both horizontal and vertical planes. Each unit includes a stepped transition surface for enhanced load distribution and a protective polymer coating for durability. The system supports rotational orientation in 90-degree increments and accommodates field modifications, such as cutting or machining, to integrate plumbing, electrical, or structural components. Applications include golf greens, playgrounds, and other installations, with overlays like artificial turf or stone veneer templated for precise alignment. The modular design reduces installation time, material waste, and labor costs while offering infinite shape configurations. The system is compatible with various surfaces, including soil, concrete, and masonry, and provides a durable, versatile foundation for both interior and exterior applications.