Toy Building Elements Heat Treatment for Durable Press Fits

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Solution Overview

Problem

Existing toy building elements face a challenge in achieving a balance between impact toughness and stress relaxation, as the addition of impact modifiers often impairs stress relaxation properties, leading to inadequate functional durability.

Innovation Solution

A method involving heat treatment of impact modified amorphous materials at a temperature of at least 40 degrees C. for 15 minutes, below the onset of the glass transition temperature, to enhance enthalpic relaxation and minimize shrinkage, resulting in improved functional durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If impact modifier is added to polymeric material, then impact toughness is improved, but stress relaxation property deteriorates

Engineering Contradiction:

Improveimpact toughnessVSAvoidstress relaxation property

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies parameter changes by controlling the glass transition temperature (Tg) of the amorphous polymeric material to be within a specific range (−50°C to 150°C) and managing enthalpic relaxation through heat treatment. This allows the material to achieve both adequate impact toughness and satisfactory stress relaxation, resolving the contradiction between impact toughness and stress relaxation property.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining amorphous polymeric material with impact modifiers while maintaining the material in an amorphous state with controlled Tg. This composite approach enables the material to exhibit both improved impact toughness from the impact modifier and adequate stress relaxation through the controlled amorphous structure and heat treatment.

Inventive Principle:

Principle #40Composite materials

2Reliability

If heat treatment temperature is increased, then enthalpic relaxation is improved, but shrinkage increases

Engineering Contradiction:

Improveenthalpic relaxationVSAvoidshrinkage

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by optimizing the heat treatment temperature to be below the glass transition temperature (Tg) of the material. This controlled temperature parameter achieves adequate enthalpic relaxation (≥0.3 J/g) while minimizing shrinkage to ≤0.2%, resolving the contradiction between enthalpic relaxation improvement and shrinkage control.

Inventive Principle:

Principle #35Parameter changes

3Strength

If toy building elements are made from impact modified material, then impact toughness is sufficient, but functional durability deteriorates

Engineering Contradiction:

Improveimpact toughnessVSAvoidfunctional durability

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent resolves this contradiction by changing the material parameters: using amorphous polymeric material with controlled Tg (−50°C to 150°C) and applying heat treatment to achieve enthalpic relaxation ≥0.3 J/g. This combination maintains adequate impact toughness while significantly improving functional durability through enhanced stress relaxation properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials comprising amorphous polymeric material with impact modifiers, where the amorphous structure with controlled Tg and the heat treatment-induced enthalpic relaxation work together to provide both impact toughness and long-term functional durability.

Inventive Principle:

Principle #40Composite materials

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

The method produces toy building elements with enhanced enthalpic relaxation of 0.3 to 4 J/g and shrinkage of 0.2%, ensuring robust constructions with improved stability and longevity of press fits without requiring additional assembly methods.

Implementation Method 1

heat treating the amorphous toy building element at a heat treatment temperature of at least 40 degrees C. for a period of at least 15 minutes, wherein the upper limit of the heat treatment temperature is 20 degrees below the onset of glass transition temperature (Tg) of the impact modified amorphous material

Methodology Applied

Scientific EffectEnthalpic relaxation:

Implementation Method 2

the upper limit of the heat treatment temperature is 20 degrees below the onset of glass transition temperature (Tg) of the impact modified amorphous material

Methodology Applied

Scientific EffectGlass transition:

Implementation Method 3

heat treating the amorphous toy building element at a heat treatment temperature of at least 40 degrees C. for a period of at least 15 minutes... resulting in improved functional durability with an enthalpic relaxation of at least 0.3 J/g and a shrinkage of maximum 0.2%

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Data Source

PatentUS20260001008A1Method of improving functional durability of toy building elements

Publication Date: 2026.01.01 LEGO AS

AI summary

A method for the manufacture of a toy building element with improved functional durability made of an impact modified amorphous material having an enthalpic relaxation of at least 0.3 J/g, such as in the range of 0.3 to 4 J/g and a shrinkage of maximum 0.2%. The present disclosure also relates to a toy building element with improved functional durability made of an impact modified amorphous material having an enthalpic relaxation of at least 0.3 J/g, such as in the range of 0.3 to 4 J/g and a shrinkage of maximum 0.2%.