Stackable Interlocking Foam Blocks for Patio Support

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Solution Overview

Problem

Existing methods for constructing raised patios and steps are labor-intensive and time-consuming, requiring significant volumes of gravel fill material that can be logistically challenging and costly, and may result in uneven surfaces and structural integrity issues due to inadequate compaction.

Innovation Solution

The use of stackable interlocking support blocks made of rigid foam, which can underfill and support patio surfaces and stairs, eliminating the need for traditional gravel fill and allowing for a modular structural fill system that is lighter, more efficient to install, and provides better stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If traditional gravel fill material is used to construct raised patios and steps, then the structural support function is achieved, but the construction becomes labor-intensive and time-consuming requiring significant volumes of fill material

Engineering Contradiction:

Improvevolume of fill materialVSAvoidconstruction efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent divides the continuous gravel fill into discrete modular foam blocks with standardized dimensions (e.g., 24" x 24" x 8"). Each block is a self-contained unit that can be independently handled, transported, and installed, replacing the need for bulk material handling and compaction operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical state and properties of the fill material from loose granular gravel requiring compaction to rigid foam blocks with inherent structural integrity. The foam blocks maintain their shape and support properties without requiring compaction, fundamentally altering the installation process from labor-intensive material placement to simple block stacking.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If traditional gravel fill material is used, then fill support is provided, but logistical challenges and costs increase due to handling large volumes of material

Engineering Contradiction:

Improvevolume of fill materialVSAvoidlogistical handling

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

By segmenting the fill material into discrete blocks, the patent enables practical handling with standard construction equipment and manual labor. Each block's standardized size allows for efficient stacking, transporting, and positioning, eliminating the logistical burden of moving and compacting large volumes of loose gravel.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The foam blocks are pre-formed and pre-positioned in their final configuration before installation. The interlocking features are预先 designed into the blocks, so no additional field preparation or compaction work is needed during installation, significantly simplifying the construction process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional gravel fill is used, then fill material is placed, but uneven surfaces and structural integrity issues result due to inadequate compaction

Engineering Contradiction:

Improvestructural integrityVSAvoidsurface evenness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent transforms the fill material from compactable gravel to rigid foam blocks that inherently maintain their shape and dimensions. The foam blocks provide consistent structural support and create uniform surfaces without requiring compaction, eliminating the variability and potential failures associated with gravel compaction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of using loose material that requires compaction to achieve density and stability, the invention uses pre-densified rigid foam blocks that inherently possess the required structural properties. The stability is built into the material itself rather than being achieved through the compaction process.

Inventive Principle:

Principle #13The other way round (Inversion)

4Productivity

If stackable interlocking foam blocks are used, then construction efficiency is improved and material handling is simplified, but the blocks require interlocking structures and geogrid interfaces adding design complexity

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidblock structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent integrates multiple functions into the foam block design: the interlocking structures (ridges and gaps) provide vertical stacking stability, the geogrid interface (apron and channel) enables horizontal reinforcement integration, and the overall block geometry ensures proper positioning. These features are merged into a single modular unit that simplifies construction despite the inherent design complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250101690A1Stackable interlocking structural foam blocks for supporting patios and other hardscape block systems

Publication Date: 2025.03.27 RISI STONE INC

AI summary

Described herein are various examples of stackable interlocking support blocks formed of rigid foam, for forming single- and multi-course support systems for assembling hardscape raised patios and/or stairs, and stair and patio systems including such support systems.