Hybrid Fully Interlocking Polyurethane Foam Panel and Polyurethane Foam Block Building Systems
Weclome to Zipblocks. We specialize in hybrid residential and commercial polyurethane foam based building systems. Our systems are hybrid because, in the course of building a wall, you can transition between using panels and blocks wherever and whenever you want. Try finding another modular building system that can do this!
Our interchangeable fully interlocking (not simply stacked) panels and resizable blocks allow you to build walls with zero waste at extreme speeds and with extreme precision.
The proprietary low cost molding technologies that we have developed are what allows us to create our suite of extraordinary fully interlocking modular building products.
Zipblock products are not being manufactured yet. We are currently seeking additional partners interested in bringing Zipblock building systems to market.
The Panels and Blocks For Our Modular Hybrid Polyurethane Foam Building Systems Are Totally Interchangeable
The proprietary molding technologies that we have developed allow us to produce low cost molds that yield a suite of extraordinary products. We have developed an essentially zero waste modular building system wherein building blocks and building panels are totally interchangeable. Our building system is as easy to use as toy-building-bricks. Shown below are some of the products that we have developed to date.
This picture illustrates why our system is hybrid. It shows a polyurethane foam block attached directly to a polyurethane foam wall panel. Try finding another modular building system that can do this!
All of our panels are "female" when they are manufactured. A female panel side can quickly be converted to a male panel side by installing lug inserts. A lug insert is shown resting on the table in front of the panel.
In this picture female side of the block is engaged with the male side of the panel. The male side of the block could just as easily have been engaged with a female side of the panel.
Zipblock Polyurethane Foam Wall Panels
Zipblock building panels are great for building walls. The panel shown in the above picture only measures 2-feet-by-2-feet-by-4-inches. A small panel like this might be used under a window sill. An assortment of larger panel sizes, like say for instance an 8-feet-by-4-feet-by-4-inch panel, could be used in wall sections that don’t have windows or doors.
When you build a wall with our hybrid Zipblock system you simply stick panels and blocks together whenever and wherever they are needed. Zipblock blocks and panels are all fully interlocking, inter-compatible, and interchangeable. Building a wall with Zipblocks is as simple as assembling a set of toy building bricks.
Our wall building system is virtually a zero waste system. While you could build all your walls and then cut out windows and doors, this is not the way our system is intended for use. Needlessly cutting parts out of panels is a waste of time and money. With our system you never have to cut out sections of panels to create openings for doors and windows. With our system you use the largest panel sizes available wherever and whenever you can and then use blocks to create window and door openings.
Zipblock Polyurethane Foam Building Blocks This picture shows a polyurethane foam building block that measures 8-feet-by-4-inches-by-4-inches. The Zipblock building system is based on cubes. The block in this picture is based on 4-inch-cubes. If you look closely you will see lines on the side of this block every 4-inches. The lines serve two main purposes. The lines allow to you determine the length of a block and they indicate where you can safely cut blocks into smaller lengths. When you cut a Zipblock into two sections there is no waste, you are only cutting a longer block into two smaller blocks(that are various lengths of 4-inch-cubes).
Because our system is based on cubes, it is extremely easy to create a manifest of supplies that are required for a project. Say for example that you wanted to build a 20-foot-long-by-10-foot-tall wall. Here is how easy it is to determine how many 8-foot long blocks you will need:
10 feet x 20 feet = 200 square feet
200 square-feet x 9 zipblock-cubes-per-square-foot = 1800 4-inch-cubes
So, to build a 20-foot-long-by-10-foot-tall wall you would need 75 8-foot-long-building-blocks. But why waste your time using a bunch of blocks when you can use 8-feet-by-4-feet-by-4-inch-building-panels in place of some of the blocks? Here is how easy to figure out what you will need if you go this route:
You can build out the first 8-foot-high-by-20-foot-long section using 5 8-feet-by-4-feet-by-4-inch-polyurethane-building-panels
The remaining 2-foot-high-by-20-foot-long section covers 20-foot x 2-foot = 40 square-feet
40 square-feet x 9 zipblock-cubes-per-square-foot = 360 4-inch-cubes
Zipblock Standard Polyurethane Foam Wall Panel Connectors
A normal sized connector like this would measure around 8-foot. Simply slide our standard connectors between adjacent wall panels or building blocks and they lock wall sections together. No need for expensive mechanical cams that must be integrated into wall panels at a factory and that restrict panel positioning to only one position. Our connectors allow you to connect wall panels and blocks together with ease and simplicity and they certainly don't restrict the position that a panel must be in. Video that illustrates how our standard connectors work.
Zipblock Notched Polyurethane Foam Wall Panel Connectors
A normal sized notched connector like this would measure around 8-foot. These notched connectors are nice because unlike standard connectors that need to slide eight feet, these only need to slide around two inches to interlock adjacent wall panels together. Simply place one of these connectors into the side of a wall panel, butt another wall panel against the first panel, and then slide down this connector to interlock your panels together.
Polyurethane Foam Lug Inserts
Lug Inserts are used to convert the sides of our building blocks and panels from female to male.
Zipblock Polyurethane Foam Block Connectors These easy-to-use connectors are used to quickly lock building blocks into position. They are especially designed to be easy to grab and place them into position with your fingers. Small stops near the top of the connector prevent the connectors from falling down the insides of blocks. The video link below illustrates their use. Video that illustrates how these connectors work.
Zipblocks Modular Building Systems Have Lots of Uses
Our blocks can be used for everything from building buildings to building tables. This section illustrates a few things that our blocks can be used for.
ICFs - Insulated Concrete Forms
With the addition of some plastic inserts our block system can instantaneously be used to create ICFs or insulated concrete forms.
When used as ICFs our system offers a lots of advantages over traditional ICF systems.
Here is how or ICF system differs from other ICF systems:
Speed - Our blocks come in lengths of up to 8 feet.
Ability to Traverse Long Spans - Because our blocks come in length of up to 8 feet and the fact that they fully interlock, you can easily assemble blocks over large areas like a garage door opening without supports being in place. Concrete supports get placed later, after all your blocks are in place.
Fire Proof - Most ICF systems are made from polystyrene, which burns. Our system is made from polyurethane foam, which does not burn.
Virtually Zero Waste - Using our toy-brick-like system you simply build the walls as if you are using toy bricks. Different block lengths are achieved by cutting longer blocks into smaller blocks. When you cut a block in two, you create two complete but yet smaller blocks.
Extreme Precision - Just as with toy-building-brick-systems our blocks assemble with extreme precision and stability.
Perfect Grid - The blocks in this picture are 4-inch blocks. If you were to build a wall with them you would see a 4-inch grid across the entire wall.
Ability To Prebuild Home Components In A Warehouse - Because our blocks fully interlock, you can build out large wall sections in a controlled environment, away from the chaos of a work site. Complete wall sections can simply be delivered to the site.
Cost - Unlike other ICF systems, the blocks used in our ICF system are NOT limited to ICF use. Our blocks can be be used to build all sorts of home furnishings and other things. This means that there is a broader market for our product. If a broader market gets leveraged, we should be able to reduce production costs. Also worth mentioning is the fact that the molds used to produce are product are very low cost.
Far Less Cutting - With traditional ICFs you have to measure and then cut. With our blocks you slice blocks in two at the 4-inch marks. After an entire wall structure has been created you can then calibrate the dimensions of openings using strips of solid foam, wood, or other materials.
Insulation - Most ICF systems are made from polystyrene. Polyurethane foam is a better insulator. Our blocks are made from polyurethane foam.
Less Concrete Blow Outs - Our blocks fully interlock and don't simply stack like all other existing ICF systems. Our blocks don't suffer from the natural proclivity to come apart when under pressure.
Less Room For Error - This goes back to the fact that our system is like a toy-building-brick-system. It's hard to mess things up when everything fits perfectly. Added to this is the fact that as you erect your walls, you'll see a perfect 4-inch grid on it.
Corner Wall Section Made From Polyurethane Foam Blocks
This picture shows a corner section of a wall that was that was built using Zipblock interlocking polyurethane foam blocks. The simplicity of the Zipblocks system makes building walls an easy process.
Note: These blocks can easily be used to build single story structures. Three-pound foam is rated at around 50-lbs-per-square-inch. Five-pound foam is rated at around 100-lbs-per-square-inch. The blocks illustrated here were created using our second generation of molds (we have since moved on to a third generation of molds that produce higher quality parts) and their foam density is about five-pounds-per-cubic-foot. Once a desired wall height is reached, a steel plate is placed along the length of the topmost blocks (the lugs get cutoff before placing the steel plate), the plate is compressed downward with threaded rod that gets anchored into a cement foundation, and then you can drop roof trusses on top of the steel plate.
Homemade Table Made From Plastic Coated Polyurethane Blocks
This dining room table top is made out 9 yellow blocks and 9 white blocks. The base is made out of a few more blocks. Have you ever seen a table that was made out of interlocking polyurethane foam blocks? A bit of white trim was added to the edge to the edge of this table. This table takes around 10 minutes to assemble. The Zipblock blocks used to build the top of this table have a colored plastic coating. More table information.
Homemade Go Kart Frame Made From Wooden Blocks
Virtually anything that you can build with toy-construction bricks can be built with Zipblocks, but on much larger scales. Zipblocks are like giant toy-construction-bricks, except Zipblocks do not merely just stack on placement, they fully interlock on placement. The go kart frame illustrated in this picture was built using wooden Zipblocks.
This wooden go kart frame is extremely strong, as wood is an extremely strong composite that is stronger and cheaper than most man-made composites. Carbon fiber composites are stronger, but they are much more expensive. One other fact that people often don't realize is that pound-for-pound wood is stronger than steel.
Homemade Bookcase Made From Polyurethane Blocks
It takes about five minutes to assemble this bookcase and around another 15 minutes to apply the trim. The polyurethane foam blocks used to make this bookcase come in lengths of up to 8 feet. Our 8-foot-long blocks have marks on them at 4-inch intervals. Need a smaller blocks? Just cut an 8-foot block into two smaller blocks at one of the 4-inch intervals. By cutting blocks at the 4-inch blocks you end up with zero waste and two complete, but smaller sized Zipblocks. More bookcase information.
Homemade Playhouse Made From Wooden Blocks
The playhouse shown here is just under six feet tall and was built using wooden Zipblocks. Ideally Zipblocks for use with children would probably be made from more child friendly materials like foam, rubber, or plastic. This playhouse can easily be built in less than an hour. If you click on the movie you can watch the entire playhouse being constructed in just a few seconds.
Building a playhouse with Zipblocks is piece of cake. All that is required is good imagination and lots of Zipblocks. If you wanted to, you could build a playhouse with several rooms or one that is several stories high. The limit to what you can build is only limited by the number of blocks that you have and what they are made from.
Imagine how much fun a child would have building their very own playhouse. What kind of playhouse would they build? Allowing a child to build a playhouse from scratch is a great way for them to have fun and it promotes creative thinking.
Homemade Desk Made From Polyurethane Foam Blocks
This homemade desk takes less than 15 minutes to assemble. This desk is very light and can be moved around with ease. One person can easily pick it up. You don't need two people to pick it up. A single person does not need to drag it across the floor.
As long as furniture is strong, does it need to be heavy? Consider this, do you think that your portable beverage cooler would be any better if it was heavier? Well, maybe a little bit, but it would be more of a pain to carry a heavier cooler around along on trips. The point here is that the light-weight-things that you can build out of our polyurethane foam blocks are both strong and they are easy to move around. More desk information.
Homemade Storage Bin Organizer Made From Polyurethane Foam Blocks and Ikea Bins
Odds are that when you go to a furniture store to buy a storage bin organizer you are going to have a limited number of choices to choose from. More than likely, your choices will be limited to 3 to 5 pieces that have set dimensions. Using our interlocking polyurethane foam blocks you can build your organizer to absolutely any dimensions that you want. Using or system you can build your organizer as tall or as wide as you want. This is just one more small example as to how great Zipblocks are. Video: Discussion about different finishes that can be applied as well as how something like this would be sold in stores. More: More videos, pictures, and info.
Homemade Sign Made From Polyurethane Blocks
You can cut our polyurethane foam blocks into small blocks/cubes and use them to build signs. In this picture we illustrate how to create the letter "i." Simply use more cubes to create larger font sizes. We simply spray painted some of the blocks/cubes black to change their color. Paint sticks very well to polyurethane foam, so long as the foam is clean and does not have any oils or nonpaintable mold release residues on it. Video: Demo of using Zipblocks to build a sign.
Soft Foam Interlocking Toy Blocks
All of our products can be produced from either rigid or soft foams. This pictures shows a soft pink and yellow foam block being flexed. These soft colorful blocks would make great toys for children. A more practical use might be to use them to build a soft, colorful wall around the inside of an infants crib. If your having guests and don't have enough beds, you could use them to make an instant sleeping mattress. A very ambitious Zipblock user could build a couch out of rigid polyurethane blocks and then overlay it with these soft foam blocks.
Note: In the future we intend to add Zipblock products that will allow you cover up exposed block lugs so that things built from Zipblocks will have a much more polished look.
Homemade Wooden Planter Box Made From Wooden Blocks
This wooden planter box made from our modular interlocking building system illustrates just one more example of what can be accomplished with Zipblocks. The wood grains in the blocks provides the planter box with a very natural look that is contrasted by the somewhat haphazard and yet uniform block placements. The combined aesthetics bring out a soothing, natural, but yet, modern look.
Homemade Wall Unit
Prior to developing molds for polyurethane foam and subsequently creating polyurethane foam blocks, we made lots of 2-inch wooden blocks because they are relatively easy and inexpensive to make. We built this custom wall unit out of basic blocks. It only takes around 30 minutes assemble it.
Was it hard to build? Absolutely not. Building this wall unit is just as simple as sticking a few toy-construction bricks together. Not to mention that it is actually fun to build things with Zipblocks. It is, after all, very rewarding to be able to work with a product that instantly allows you to build anything that you want.
Let's say that you wanted to create your very own custom wall unit in your living room that covered an entire wall from floor to ceiling. Let's assume that your wall is 20 feet long and 12 feet tall. Can you imagine how much it would cost you if you walked into your local home supply center and ordered a custom-made-wall-unit? It would probably cost you a fortune in both labor and materials. Now picture yourself walking into the same store and ordering a Zipblock kit, having the kit delivered to you home, and then building your very own wall unit all in a days time. The cost would of course be much less and you would have a custom wall unit that you designed and built all by yourself. This would indeed be a much more rewarding experience.
What we just spoke about is more than ideal. What's more is that when you build with Zipblocks and you make a mistake. No problem. Just disassemble your mistake and fix it. Moving to another home and the living room is smaller? Again, no problem. Just disassemble your wall unit, ship it to your new home, and when you get there build another custom wall unit that suits to your needs.
You know, the great thing about these blocks is that you can build just about anything with them. Imagine how much fun you could have building some really cool workbenches in your garage or putting up some giant shelves in there. How about building a dog house for your dog or a playhouse for your child or a closet organizer?
You see there are simply countless things that you can build with our blocks and if you ever get tired of what you built. Well, just break it down and use your blocks for something else! Zipblocks are essentially a product that never loses its value or usefulness.
Hey. The power went out and there is a snowstorm outside. No problem. Just break down those Zipblock shelves in the garage and use them for firewood. They make excellent logs. After the storm is over just pickup a few new ones at the store and fix the shelf.
One last comment about the wall unit shown in the above picture...the holes you see can be covered up by snapping finishing boards onto them.
Zipblock Pictures That Are And Are Not Tagged To Site Content Can Be Found Here
You’ll find a wide range of interesting Zipblock pictures sorted in random order here. If you click on a picture a detailed description will appear. If you click on the picture within the description page you can view the original-full-sized-picture.