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.

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.