Stackable Block With Stepped Perimeter For Interlocking And Flat Packing
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Solution Overview
Problem
Existing stackable blocks for construction and toys are solid and lack interlocking properties, requiring mortar for secure assembly and resulting in high transportation and storage costs due to their dense and heavy nature.
Innovation Solution
A stackable block design featuring a wall with an inner and outer surface, where at least a portion of the inner surface is vertically offset from the outer surface, creating stepped configurations on the upper and lower perimeters. This design allows the blocks to be folded and transported in a flat, disassembled form, improving packing efficiency and enabling interlocking capabilities without the need for mortar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blocks are made solid and dense for structural strength, then strength is improved, but weight and transportation cost increase
Solution Approach 1:
The block is divided into multiple hollow cavities within its structure, segmenting the solid material into separate chambers. This segmentation reduces the overall weight and material usage while maintaining structural integrity through the distributed cavity design, directly addressing the contradiction between strength and weight
Solution Approach 2:
The block employs a porous structure with multiple hollow cavities throughout its body. This porous material approach reduces density and weight compared to solid blocks, while the cavities are positioned and sized to maintain adequate structural strength for building applications
2Weight of moving object
If blocks are made hollow to reduce weight, then weight is reduced, but structural strength decreases
Solution Approach 1:
Different regions of the block have different properties - the walls between cavities maintain sufficient thickness and density for structural strength, while the cavity regions provide weight reduction. This local quality differentiation allows the block to be lightweight overall while maintaining strength where needed
Solution Approach 2:
The block combines solid material walls with hollow cavity spaces to create a composite structure. The solid walls provide strength and structural integrity, while the hollow spaces reduce weight, achieving a balance between these two opposing requirements through material distribution
3Stability of the object's composition
If blocks are transported in assembled form, then structural integrity is maintained, but storage space efficiency decreases
Solution Approach 1:
The block incorporates collapsible walls with hinge joints that allow the structure to transition between an assembled three-dimensional form for use and a collapsed flat form for storage and transport. This dynamic capability enables the block to adapt its volume while maintaining structural integrity when assembled
Solution Approach 2:
When collapsed, the block's walls fold inward to create a compact, space-efficient configuration that nests the block's components within a minimal volume, dramatically reducing storage space requirements compared to the assembled form
4Ease of manufacture
If traditional solid blocks are used without interlocking features, then manufacturing is simple, but assembly requires mortar increasing complexity
Solution Approach 1:
The interlocking features are integrated directly into the block's wall structure during manufacturing, merging the structural walls with the interlocking mechanisms. This combination eliminates the need for separate mortar applications or additional assembly components, reducing overall assembly complexity while maintaining manufacturing simplicity
Data Source
AI summary
A stackable block, comprising: a wall having an inner surface and an outer surface, the wall comprising a strip of material having a first end and a second end with a plurality of transverse fold lines spaced there between, the wall configured to define a structure having an upper perimeter and a lower perimeter, wherein the structure is formed by the strip being folded about the transverse fold lines and the first and second ends being connected together, and wherein at least a portion of the inner surface is vertically offset from the outer surface such that the upper and lower perimeter have stepped configurations.