FOAM BLOCKS HAVING CONNECTION CHANNELS

Abstract

A method of forming a foam block capable of being securely assembled to a different foam block to create a structure that is larger than the foam block is described herein. The method includes the following features. The foam block is received. Channels are formed in at least one side of the foam block. At least some of the channels are formed to accept a securing member that restricts vertical and horizontal movement of the foam block when the foam block is secured to the different foam block.

Claims

1. A method of forming a foam block capable of being securely assembled to a different foam block to create a structure that is larger than the foam block, the method comprising: receiving the foam block; and forming a plurality of channels in at least one side of the foam block, wherein at least some of the plurality of channels is formed to accept a securing member that restricts vertical and horizontal movement of the foam block when the foam block is secured to the different foam block.

2. The method of claim 1, further comprising: forming the securing member from foam, wherein the securing member has a shape that enables the securing member to be inserted into at least one channel among the plurality of channels formed in the foam block.

3. The method of claim 1, wherein forming a plurality of channels in at least one side of the foam block comprises forming channels that create a void shape inside of the perimeter of the foam block as received, wherein the void shape is one of a T-shape, an X shape, or a keystone shape.

4. The method of claim 3, wherein forming the securing member comprises forming the securing member to have a shape matching the void shape.

5. The method of claim 3, further comprising forming a plurality of channels in a different foam block, wherein at least one channel formed in the different foam block aligns with at least one channel that was formed in the foam block when edges of the foam block and the different foam block are aligned.

6. The method of claim 5, wherein a length of each edge of the received foam block is at least two feet each.

7. The method of claim 5, wherein forming a plurality of channels in at least one side of the foam block comprises forming the plurality of channels using a hot wire foam cutting table.

8. The method of claim 6, further comprising: forming a dimensioned block that has different dimensions than the foam block; forming at least one channel in the dimensioned block, wherein the at least one channel of the dimensioned block is formed at a location of the dimensioned block such that the at least one channel aligns with a given channel of the foam block when a corner of the dimensioned block is aligned with a corner of the foam block.

9. The method of claim 8, wherein forming the dimensioned block comprises forming the dimensioned block to have: a depth that matches the depth of the foam block; a width that does not match the width of the foam block; and a height that does not match the height of the foam block.

10. A foam block capable of being securely assembled to a different foam block to create a structure that is larger than the foam block, wherein the foam block has a plurality of channels defined in at least one side of the foam block, and wherein at least some of the plurality of channels is defined to accept a securing member that restricts vertical and horizontal movement of the foam block when the foam block is secured to the different foam block.

11. The foam block of claim 9, wherein the securing member has a shape that enables the securing member to be inserted into at least one channel among the plurality of channels formed in the foam block.

12. The foam block of claim 9, wherein: the plurality of channels are defined to have a void shape inside of the perimeter of the foam block; and the void shape is one of a T-shape, an X shape, or a keystone shape.

13. The foam block of claim 11, wherein the securing member have a shape matching the void shape.

14. The foam block of claim 9, wherein a length of each edge of the foam block is at least two feet each.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a perspective view of an example foam block.

[0029] FIG. 2 is a perspective view of an example foam block.

[0030] FIG. 3 is a perspective view of an example foam block.

[0031] FIGS. 4A-4C are cross-sectional views of example retainers that can be used with aspects of this disclosure.

[0032] FIG. 5 is a perspective view of an example structure constructed with the previously illustrated foam blocks.

[0033] FIGS. 6A-6B are schematic drawings comparing construction methods.

[0034] FIG. 7 is a flowchart of an example method that can be used with aspects of this disclosure.

[0035] Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

[0036] Movie and television sets and other large decorative structures, such as elements of theme parks, are often used on a temporary basis, which leads to a large amount of wasted materials, e.g., foam material. Furthermore, these structures are often formed by starting with a large foam block to provide structural rigidity, and then cutting away significant portions of the foam to arrive at the desired structure. This leads to even more wasted materials.

[0037] For example, to create a railroad tunnel for a movie set, the construction process may start with a 20′×20′×40′ piece of foam, which is carved out to create the tunnel structure, which could require carving out 30-40% or more of the foam, which is simply wasted. If this same railroad tunnel were constructed using smaller interconnected foam blocks, like those described herein, most of the wasted foam could be eliminated because the blocks could be arranged and interconnected to create a shape much closer to that of the tunnel structure without having to carve out the tunnel structure from a solid larger piece of foam.

[0038] The subject matter described herein relates to a structural system of foam blocks and retainers acting as securing members. The foam blocks can include pre-cut channels, also referred to as connection channels, which are configured to receive the retainers to secure two or more foam blocks together. The cross-sectional shape of the channels and the retainers are substantially the same (or identical) within standard manufacturing tolerances to allow for rapid construction of initial structures. The foam blocks can come in a variety of different sizes that are configured to interface with each other and the retainers. In some instances, channels can be formed on-site in instances where there is a unique building need.

[0039] FIG. 1 is a perspective view of an example foam block 100. The example foam block 100 is depicted as a rectangular prism having a height 102, width 104, and depth 106. Note that the designation of height 102, width 104, and depth 106 are provided to aid in the description, and are not intended to be limiting. Throughout this disclosure, shapes of various foam blocks are described as rectangular prisms in shape; however, other shapes can be used without departing from this disclosure, for example cylinders, octagons, and semi-spheres can be used. The foam block 100 itself can be made of a variety of different foams, for example, expanded polystyrene. In some implementations, extruded polystyrene or rigid polyurethane can be used without departing from this disclosure.

[0040] The density and material of the foam block 100 can vary depending upon the application. For example, if greater structural rigidity is desired, then a denser foam may be used, while if ease of shaping and/or carving is desired, a lower density foam can be used. While primarily described throughout this disclosure as being constructed of foam, other base materials can be used for the foam block 100 without departing from this disclosure, for example, wood, metal, or plastic can be used.

[0041] Each foam block 100 has, defined within its outer walls, at least one channel 108 extending the length of the depth 106 of the foam block 100. The channel 108 in at least one side of the foam block defines a void shape inside of the perimeter (encircling the height 102 and the width 104) of the foam block 100. Various void shapes are described throughout this disclosure. The channel 108 itself is configured to receive and secure a securing member, or a retainer, within the foam block 100. The retainer is configured to couple the foam block 100 to a second foam block. Example retainers are described below.

[0042] The foam block 100 includes two channels (a first channel 108a and a second cannel 108b) on each side of its outer perimeter. The number of channels 108 per side can vary based upon the dimensions of the foam block 100 and the desired retention strength retaining two foam blocks together. In some implementations, the cross-sectional shape, or void shape, of each channel 108 is substantially the same (or identical) within standard manufacturing tolerances. In some implementations, different channels 108 can have different cross-sectional shapes, or void shapes. As depicted in FIG. 1, the foam block 100 has T-shaped voids that are configured to receive an I-shaped retainer that will connect the block 100 with another block having a T-shaped void.

[0043] FIG. 2 is a perspective view of another example foam block 200. Foam block 200 is similar to foam block 100, but has different dimensions. For example, the foam block 200 has a greater width 104 and height 102 than the foam block 100. In some implementations, the depth 106 can be different as well. The foam block 200 also includes additional channels 108, more specifically, the foam block 200 has four channels (a first channel 208a, a second channel 208b, a third channel 208c, and a fourth channel 208d) per side around the perimeter of the foam block 200 versus the two channels (108a, 108b) present on each side of the perimeter of the foam block 100. In some implementations, the distance between two adjacent channels along a same side of the foam block 200 is the same distance as is between the two channels (108a, 108b) of the foam block 100.

[0044] FIG. 3 is a perspective view of another example foam block 300. The foam block 300 is similar to foam blocks 100, but has different dimensions. For example, the foam block 300 has a smaller width 104 and height 102 than the foam block 100. In some implementations, the depth 106 can be different as well. The foam block 300 includes fewer channels 108 than the foam block 100, more specifically the foam block 300 only includes a single channel 308a along each side of the perimeter of the foam 300. In some implementations, a distance between the single channel 308a and an edge 310 of the foam block 300 can be one half the distance between the two channels (108a, 108b) on a single side of the foam block 100. Of course, the channels could be offset from the center of the foam block 300 depending on the structure being built. The channels can be formed, for example, by using a hotwire table (or another machine or instrument) to cut the voids in the foam block 300, or other foam blocks described herein.

[0045] As described throughout this disclosure, the channels 108 in the various foam blocks (100, 200, 300) are configured to receive a securing member, or retainer. Such a component is used to hold the various foam blocks together. FIGS. 4A-4C are cross-sectional views of example retainers 400 that can be used with aspects of this disclosure.

[0046] FIG. 4A is a side cross sectional view of an example I-shaped retainer 400a. The I-shaped retainer 400a has parallel portions 402a, that are configured to be parallel to the sides of the foam blocks in which the channels 108 are defined, and a perpendicular portion 404a that is configured to extend between the foam blocks that are being secured by the retainer 400a, e.g., through an interface 410 between two blocks, and into an adjacent foam block. The I-shaped retainer 400a has a cross-sectional area that corresponds to the T-shaped channels described throughout this disclosure.

[0047] FIG. 4B is a side cross-sectional view of an example X-shaped retainer 400b. The X-shaped retainer, as implied by the name, has two diagonal portions 402b that cross the interface 410 between two blocks. In some implementations, the two diagonal portions 402b are perpendicular to one another. In some implementations, the diagonal portions are symmetrical across the interface 410 between two blocks. In use, each of the diagonal portions extends into corresponding voids that are formed in two blocks that are being secured together by the retainer 400b. The X-shaped retainer 400b has a cross-sectional shape that corresponds to V-shaped channels described throughout this disclosure.

[0048] FIG. 4C is a side cross-sectional view of an example double keystone-shaped retainer 400c. The double keystone-shaped retainer 400c includes a taper with a wider portion 402c deeper within the block and a thinner portion 404c towards the interface 410 between two blocks.

[0049] In general, the cross-sectional shape of the retainers 400 matches or corresponds to the shape of the channels 108. More specifically, the shape of the retainers 400 tends to be a double/mirror the shape of each channel. For example, if the channel is T-shaped, the connector that would attach two of those channels would be I-shaped. Alternatively or in addition, V-channels would be connected with X-shaped retainers 400b, and keystone channels with a “double keystone” shape illustrated in FIG. 4C. While several example shapes of the retainers 400 have been illustrated and described, other shapes can be used without departing from this disclosure. In general, the shape of the retainers 400 and channels 108 creates an interface between the retainer 108 and a foam block, securing the retainer 400 to at least one block, and in some instances, two blocks to one another by the retainers 400. That is, the retainers 400 and channels 108 can be any shape that restricts horizontal (shear) and vertical (tensile) movement of the block. In other words, the shape of the retainer 400 keeps the retainer within the channel 108 when forces try to directly pull blocks apart or when a force tries to slide adjacent blocks in different directions along their perimeters (perpendicular to the channels). The retainers 400 can be made of several different materials, for example, foam, plastic, or metal. In general, the retainers are as dense as or denser than the foam blocks. In some implementations, the retainers 400 can be made of the same material as the blocks.

[0050] FIG. 5 is a perspective view of an example structure 500 constructed with the previously illustrated foam blocks (100, 200, 300) and T-shaped retainers 400a. As illustrated, the foam blocks each have a square cross-section, that is, the width and height for each individual block is equal. In the illustrated implementation, the foam block 200 has a height 102 and width 104 that is twice that of the foam block 200, which has a height 102 and width 104 twice that of foam block 300. While illustrated with such sizing, the foam blocks can be made in a variety of sizes. For example, the blocks can be one foot by one foot by one foot, two feet by two feet by two feet, or four feet by four feet by four feet. In some implementations, the foam blocks may be shapes other than cubes. For example, the foam blocks can be 3 feet by four feet by sixteen feet, or three feet by four feet by eight feet.

[0051] In general, the blocks are sized and include channels 108 that can be aligned with one another to form structures, such as structure 500. A structure of blocks includes at least two blocks connected by at least one retainer 400a or securing member. The retainer 400a is secured to a first foam block and a second foam block by channels 108 defined by the first foam block and the second foam block. In general, the connected blocks abut one another when connected by a retainer 400a (or 400b or 400c).

[0052] In some implementations, two blocks of the same dimensions, such as the illustrated blocks 200, can be connected within a structure. In some implementations, blocks of different dimensions, such as foam block 100 and foam block 300, or foam block 100 and foam block 200, or foam block 300 and foam block 200, can be connected to one another to form a structure. While primarily illustrated as using I-shaped connectors 400a and T-shaped channels, other connector shapes can be used, for example, the X-shaped connector 400b (FIG. 4B) with a V-shaped channel or the double-keystone-shaped connector 400c (FIG. 4C) with a keystone-shaped channel.

[0053] The location of the channels 108 in different blocks can vary depending on the desired structure; however, for the most purposes, the channels between blocks are aligned as shown in the FIG. 5. That is, blocks of different sizes can be used to help create an initial shape of the structure. There are instances where using the same size blocks and offsetting them, for example, overlapping blocks as to break continuous seams, may be used to create a stronger structure. In such instances, the location of the channels 108 may be different between blocks to accommodate the offset.

[0054] In some implementations, after an initial structure such as structure 500 is constructed, the foam blocks may have portions cut away, or sculpted, to arrive at a final structure. Such a process can be useful when structures need to be created rapidly, such as for stage plays, movie sets, or non-supporting internal walls of an existing structure. This process can also be useful for creating movie and television sets as well as ornamental structures in other scenarios, e.g., theme parks, large decorative statues or art installations, decorative building columns, or decorative walls. Because foam is an insulator, such a process can also be useful in creating soundproofed walls or insulated walls (or a roof) of a building.

[0055] FIGS. 6A-6B are illustrations comparing the traditional process 600a of creating a structure using foam to the process 600b of creating the same structure using the foam blocks discuss herein, which have the connection channels. In the present example, foam is being used to create a railroad tunnel 602. As shown, the traditional process 600a begins with a single large piece of foam 604, while the process 600b uses a set of interconnected smaller foam blocks 606. To create the tunnel 602 using the traditional process, all of the foam that is in the area defining the opening of the tunnel 602 must be removed, and is typically discarded. Meanwhile, using the interconnected blocks 606 in the process 600b only requires that the blocks 606a and 606b be rounded, and that a small portion of the blocks between 606a and 606b need to be shaped. This results in significantly less waste than the process 600a. Furthermore, when it is time to deconstruct the structure, the structure created using the process 600b can be broken down into conveniently sized blocks, which can be transported and recycled much more easily than the structure created by the process 600a. In some implementations, a small piece of metal can be included in the securing members, or inserted into designated locations to facilitate the identification of seam locations (i.e., locations where two foam blocks are connected). This enables more efficient deconstruction even after a top layer of foam or a hard coating may be placed over the initial foam structure (e.g., ornamental features are crafted with soft foam over the base structure), which will obscure the seams between the foam blocks. The pieces of metal can be located, for example using a metal detector. In situations where a hard coating is used, the structure is coated with a liquid polyurethane, glue, or water-based hard coat, or other similar product, which allows the fabricator to texture and/or paint the structure.

[0056] FIG. 7 is a flowchart of an example method 700, of forming a foam block capable of being securely connected to a different foam block. As discussed above, foam blocks can be securely connected to create a structure that is larger than the foam block. At 702, a foam block is received. At 704, channels are formed in at least one side of the foam block. At least some of the channels are formed to accept a securing member or retainer (400a, 400b, 400c). The securing member or retainer prevents movement of the foam block in shear or in tension relative to a different foam block when the foam block is secured to the different foam block. Forming the channels 108 in at least one side of the foam block includes forming channels that defines a void shape inside of the perimeter of the foam block as received. In some implementations, the void shape is one of a T-shape, a V-shape, or a keystone shape. The channels 108 can be formed, for example, using a hotwire table (or another machine or instrument, such as a knife) to cut the voids in the foam block, or other foam blocks described herein.

[0057] A retainer 400 or securing member is formed. The retainer or securing member has a shape that enables the retainer or securing member to be inserted into at least one channel 108 among the multiple channels 108 formed in the foam block. In some implementations, the retainer 400 or securing member is formed of foam, plastic, or metal. The retainer 400 or securing member can be made of other materials without departing from this disclosure. Forming the retainer 400 or securing member includes forming the retainer 400 or the securing member to have a shape corresponding to the void shape. In some implementations, the retainers 400 or securing members can be used to form the channels 108.

[0058] Channels 108 can also be formed in the different foam block. In some implementations, at least one channel 108 formed in the different foam block aligns with at least one channel 108 that was formed in the foam block when edges of the foam block and the different foam block are aligned. In some implementations, forming the channels 108 in at least one side of the foam block or the different form block includes using a hot wire foam cutting table. In some implementations, forming the channels in at least one side of the foam block or the different form block includes using a retainer 400 or securing member.

[0059] In some implementations, a dimensioned block, that has different dimensions than the foam block, is formed. At least one channel 108 is formed in the dimensioned block. The channel 108 of the dimensioned block is formed at a location of the dimensioned block such that the at least one channel 108 aligns with a given channel 108 of the foam block when a corner of the dimensioned block is aligned with a corner of the foam block. That is, the channel 108 in the dimensioned block is a same distance from the corner of the dimensioned block as a distance between the channel 108 in the foam block and the corner of the foam block, helping to ensure alignment.

[0060] In some implementations, forming the dimensioned block includes forming the dimensioned block to include a depth 106 that matches the depth of the foam block. In some implementations, forming the dimensioned block includes forming the dimensioned block to include a width 104 that does not match the width of the foam block. In some implementations, forming the dimensioned block includes forming the dimensioned block to include a height 102 that does not match the height of the foam block.

[0061] The foam block, the different foam block, and the dimensioned foam block can all be used to create an initial structure, with their aligned channels 108 and securing members (retainers 400), which can then be sculpted, for example, by an artisan.

[0062] While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0063] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

[0064] Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.