Amusement devices: toys – Construction toy – Resilient interlocking joint
Reexamination Certificate
2002-04-09
2003-11-18
Ackun, Jacob K (Department: 3712)
Amusement devices: toys
Construction toy
Resilient interlocking joint
C446S124000
Reexamination Certificate
active
06648715
ABSTRACT:
BACKGROUND
1. Field
The invention relates to modular construction systems that have releasable snap-fit connection elements that are actually interlocking features of the construction elements themselves, which can be integrated into many differently shaped construction elements and be useful in a variety of fields.
2. Prior Art
Construction systems incorporating various methods of connecting construction elements together are known in the art. Many construction elements connect primarily on one or two faces. One construction toy that connects on two faces is the brand “Lego Classic,” shown in U.S. Pat. No. 3,005,282. A stud and friction-fit type of connection is used on what are generally considered to be the top and bottom faces of a construction block. This type of connection system is deficient however, as these blocks may not be connected on the other faces, such as side-to-side in a single layer in order to create a span, or overhang, or to construct a beam projecting outwards. Such blocks can be inexpensively produced with simple plastic injection molds. The same studs could be added to more faces, however this would result in more expensive production.
Construction elements with connection elements on more than two faces have been developed. The most common form seen in toys is of the brand “Lego Technic,” which uses studs and cavities on the top and bottom faces, and through-holes projecting through two of the remaining faces of block and beam construction elements. Snap-fit pins pushed through the holes can be used to connect two or more construction elements together. Such construction elements require more expensive molds to produce than the “Lego Classic” type because the draw in the mold is in more than one direction. Using holes rather than extra studs and cavities results in more flexibility in construction. Engaging many construction elements together side-to-side with snap-fit pins is not considered very practical however.
Another method of engaging construction elements together that is less common in toys but more popular in larger construction systems is the dovetail connection. For example, U.S. Pat. No. 2,619,829 by “Tatum” shows a hollow construction block, suitable for blocks made of concrete, which contains one fixed male, and one or more female dovetails in the side of the block. A separate double male connecter is also provided to connect two opposing female dovetails when required. Such a system can connect blocks together on all sides. As well, both the male as well as female dovetails extend only halfway down the block's sides. This results in a bottom ledge in the female dovetail and prevents the captive male dovetail from sliding through. Of course there is nothing to prevent the male dovetail from sliding back out again. The block faces having dovetails can be secured in only five of six spatial directions. When such blocks are used in multi-layer constructions such as walls, most of the half-height male and female dovetails become captive between adjacent blocks. This reduces the problem of connections coming apart somewhat. There is a problem however in using this system to construct single layer longitudinal objects such as floors or beams.
A similar half-height dovetail connection method is used on toy blocks of the brand name “Kitslink,” which is shown in U.S. Pat. No. 6,050,044. In this system however, a stud and cavity friction-fit type of connection is used to connect blocks on the top and bottom faces as well. This design allows construction elements to be engaged to each other on all six faces, but still the dovetail sides can be secured in only five of six spatial directions. This is more of a problem with toys where more complex structures are constructed as opposed to constructing walls in the previously mentioned construction system. One way of keeping the dovetails from sliding apart would be to use a friction fit, but this would make the blocks quite hard to put together and especially to take apart. A real disadvantage of this system when used for toys is that the blocks cannot be pushed together in the longitudinal direction of the faces that contain the dovetails. Instead, the block with the male dovetail must be lowered vertically into the female dovetail. As well, when dismantling the structures, the dovetails must be withdrawn in the opposite direction of the assembly. The right direction of disassembly is not clear when viewing the built structures. When single layer, long beamlike objects are assembled, the half-height dovetails can be subjected to tremendous stress if they are handled roughly during play. It is not very difficult to tear apart the dovetails, in which case the blocks become permanently damaged.
Yet another toy block with brand name “Morphun” is shown in U.S. Pat. No. 5,957,744. This block uses full-length female dovetail or star shaped grooves in the block sides. To connect the blocks together, they are placed side-by-side and a star shaped connecter is inserted into the facing grooves. This design also does not require studs or other connecting means on the top and bottom faces because the star shaped connecters can be taller than the blocks and so can join blocks both vertically as well as longitudinally. The star shaped connecter is slightly flexible and is designed to have a reasonable friction-fit or a mild compression lock. This makes the structures much more secure than with the previous dovetail design, and blocks can be secured on six faces in six spatial directions. However the blocks still cannot be pushed together longitudinally on the dovetailed sides and must be carefully slid apart from the star shaped connecters to avoid being damaged. The star shaped connecters are generally small and so could cause choking in children if they are swallowed.
While both the “Kitslink” and “Morphun” designs result in much more elaborate constructions than can be created using the standard “Lego Classic” construction blocks that locate on only two faces, both have two inherent problems. Construction using these blocks must be done in layers, as the blocks cannot be engaged longitudinally or inserted in the middle of structures. As well, the blocks are meant to be disassembled by carefully sliding apart the blocks or connection elements, and rough disassembly can result in severe damage to the connection elements on the blocks.
The solution to the problem of careful assembly and disassembly has often been to use a type of snap-fit connection. In U.S. Pat. No. 2,885,822 by “Onanian,” a block and beam construction system using split hollow blocks with holes in every face is shown. A round double male snap-fit connection element with a pair of outward facing ribs is used to connect blocks together. Such structures can be snap-fit together or apart and can be secured on six faces in six spatial directions. While this design solves the problems of damage to blocks through rough disassembly, the blocks can only be inserted directly towards the face. This design is therefore deficient in that it does not allow for blocks to slid into a space. As well, the production of hollow two part blocks is expensive and the small separate male connection elements are difficult to remove and could also be a choking hazard for children.
A popular snap-fit strut type of construction system with brand name “K'nex” is show in U.S. Pat. No. 5,061,219. In this case, male rods are snap-fit sideways into female fittings, but now engaging or separating along the length of the rods is not possible. It is true that the connections don't need to be carefully slid apart, but separation by a bending action can result in high point contact loads that may result in some damage to parts. A somewhat similar rod type construction system is also shown in U.S. Pat. No. 5,704,186 by “Alcalay”.
Another design shown in U.S. Pat. No. 5,518,434 by “Ziegler” shows a toy construction system using beams having a pair of rounded flexible male fingers which snap-fit into a female square recess. Beams are snap-fit together end to end but not
McIntosh Eric G.
Wiens Benjamin I.
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