Polyurethane Foam Blocks with Interlocking Cavities for Modular Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing affordable housing solutions using modular foam components face challenges due to high shipping costs and limitations of expanded polystyrene (EPS) in terms of thermal resistance, moisture permeability, fire resistance, and wind load resistance.
Innovation Solution
The use of polyurethane foam blocks with a base having recesses, walls defining an interior, a top surface with connective components, and partitions dividing the block into cavities, allowing for interlocking and stacking to form structural entities like homes and walls, using a portable molding device for on-site production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular foam components are manufactured and shipped to building sites, then housing structures can be assembled efficiently, but shipping costs become prohibitively expensive due to the lightweight nature of foam
Solution Approach 1:
The foam block is divided into multiple cavities separated by partitions, allowing the same block to serve both as structural component and insulation material, thereby reducing the number of separate components needed and lowering shipping costs while maintaining assembly efficiency
Solution Approach 2:
The foam block integrates multiple functions: structural support through the base and walls, thermal insulation through the closed-cell foam material and cavities, and moisture resistance through the polyurethane material properties, eliminating the need for separate insulation and structural components
2Ease of manufacture
If expanded polystyrene (EPS) is used as the base material for modular components, then manufacturing is simplified, but thermal resistance, moisture permeability, fire resistance, and wind load resistance are insufficient
Solution Approach 1:
The patent changes the material parameters by using polyurethane foam instead of EPS, achieving superior thermal resistance (R-value of 5-6 per inch), moisture resistance, fire resistance, and wind load capacity while maintaining the modular block structure and manufacturing process
3Productivity
If traditional bulky machinery is used to create EPS modular components, then production capacity is sufficient, but the ability to create components at remote construction sites is difficult
Solution Approach 1:
The system enables on-site production of foam blocks using a portable molding device that can be transported to remote construction sites, eliminating the need for centralized manufacturing and expensive shipping while maintaining production capacity through local fabrication
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces shipping costs, enhances structural integrity and insulation, and allows for cost-effective, resilient, and energy-efficient construction of housing and structural entities in remote or inaccessible areas.
Implementation Method 1
enhances structural integrity and insulation
Data Source
AI summary
A polyurethane foam block can include a base having a plurality of recesses and a top surface having a plurality of connective components protruding outward from the top surface where each connective component of the plurality of connective components can align with a recess of the plurality of recesses. The polyurethane foam block can include a plurality of sidewalls extending upward from the base and defining an interior and a plurality of partitions extending from the base to the top surface to divide the block into a plurality of cavities. A wall can include base blocks and header blocks. The header blocks can be shaped and constructed similarly to the base blocks with one exception being the header blocks can include an-upward facing channel cutout. The wall can include a beam extending through channels of header blocks.