Toy block construction kit made of elastomeric material

Abstract

A toy building block (12) molded from a thermoplastic elastomer. This enables the block (12) to be elastically stretched in any direction. Each toy building block (12) has a body (26) having a top surface (14) and a bottom surface (16). A male connector tab (18) extends from the top surface (14). The female connector receptacle (20) extends into the bottom surface (16) of the body (26). At least one internal cavity (30) is molded within the body (26). The internal chamber (30) is separate and distinct from the female connector receptacle (20). The interior chamber (30) extends into the male connector projection (18). Each internal chamber (30) may be empty or filled with a filler material (46). The filler material (46) may be a liquid, a gel, and lubricating particles and is preferably visible through a molded thermoplastic elastomer.

Description

Technical Field

[0001] In general, the present invention relates to the structure of toy blocks, which are designed to be interconnected so that different configurations can be created. More specifically, the present invention relates to the structure of toy blocks and the materials used to manufacture toy blocks. Background Technology

[0002] There are many types of toy blocks designed to be interconnected. One of the most popular toy block sets is sold under the LEGO® trademark and was originally described in U.S. Patent No. 3,005,282 to Kirk. Despite the popularity of such toy blocks, they do have some problems inherent in toy construction. Most interconnected toy blocks are made of hard plastic. This gives the toy blocks the ability to “click” together and remain firmly interconnected until manually pulled apart. However, there are some issues with product safety regarding interconnected toy blocks made of hard plastic. Toy blocks made of hard plastic have hard edges and corners, making it painful to step on with bare feet. Therefore, they can injure their feet or even cause them to fall when people step on such products. In addition, if a toy block is accidentally swallowed, a hard plastic block can remain in a child's throat and / or intestines. Furthermore, hard plastic blocks, as well as larger structures made of such blocks, can break and snap if stepped on, dropped, or subjected to other impacts.

[0003] Beyond product safety concerns, hard plastic toy blocks feature convex and concave features that interconnect with a slight interference fit. This necessitates very tight tolerances in the manufacture of such toy blocks and in the raw materials used in their molding. If tolerances or materials vary, the toy blocks may become difficult to interconnect and / or pull apart. This complicates the manufacturing and supply chain processes, making the production of such products both difficult and expensive.

[0004] In existing technology, toy blocks are made of materials softer than hard plastic. Using such products, the blocks are typically made of open-cell or closed-cell foam. This makes the blocks too large to swallow and too hard to bite. In this way, if these blocks or structures made of blocks are dropped, thrown, or bitten by a child, no injury will occur.

[0005] Coppel's U.S. Patent Application Publication No. 2019 / 0381417 illustrates toy building blocks made of molded polymer foam. The polymer foam makes the building blocks soft and compressible to a limited extent. A major problem with polymer foam is that, although it can be elastically compressed, it has low tensile strength and even lower shear strength. Therefore, such foam materials can only be used on large blocks in which the mass of the foam provides strength. If such a foam material is used on small blocks, the protrusions formed on the blocks will easily break off from the blocks when they are interconnected and manipulated.

[0006] Given the current state of the art, there is a need for improved toy building blocks that allow the blocks to be made of soft materials and that also enable the blocks to interconnect well and resist breakage, even when made into small pieces. This need is met by the invention described below and claimed. Summary of the Invention

[0007] This invention relates to a kit of toy building blocks and the structure of at least some of the blocks in the kit. All toy building blocks in the kit are molded from a thermoplastic elastomer. This allows each block to be elastically stretched by at least 10% in any direction without damage. Each toy building block has a body having a top surface and a bottom surface. One or more convex connector protrusions extend from the top surface. Similarly, one or more concave connector receptacles extend into the bottom surface of the body. In the kit, the blocks can appear in various shapes and sizes. In some blocks, the body is molded with empty floating protrusions. In some other blocks, at least one internal cavity is molded. The internal cavity is separate from and distinct from the concave connector receptacle. However, one or more internal cavities do extend into the convex connector protrusions.

[0008] Each internal cavity can be empty or filled with a filler material that does not inhibit the flexibility of the body. The filler material is selected from liquids, gels, and lubricating particles and is preferably visible through molded thermoplastic elastomers. Attached Figure Description

[0009] To better understand the invention, reference is made to the following description of exemplary embodiments thereof, which are considered in conjunction with the accompanying drawings, in which:

[0010] Figure 1 An exemplary kit of toy building blocks is shown;

[0011] Figure 2 A top perspective view of a first type of block from a toy building block kit is shown;

[0012] Figure 3 It shows Figure 2 The bottom perspective view of the block shown;

[0013] Figure 4 It shows Figure 2 and Figure 3 The cross-sectional view of the block shown in the image;

[0014] Figure 5 A cross-sectional view of two blocks joined in a compressed manner is shown;

[0015] Figure 6 A cross-sectional view of two blocks separated under tension is shown;

[0016] Figure 7 A cross-sectional view of a toy construction block filled with filler material is shown;

[0017] Figure 8 A perspective view of a thin toy construction block is shown; and

[0018] Figure 9 It shows Figure 8 The cross-sectional view of the thin toy building block shown. Detailed Implementation

[0019] While the invention can be embodied in many ways in constructing toys, only a few exemplary embodiments are illustrated. Exemplary embodiments are shown for purposes of explanation and illustration. Exemplary embodiments were chosen to illustrate some of the best modes contemplated by the invention. However, the illustrated embodiments are merely exemplary and should not be considered limiting in interpreting the scope of the appended claims.

[0020] See Figure 1 The image shows a kit 10 of toy building blocks 12. The toy building blocks 12 have various shapes and sizes. Each toy building block 12 has a top surface 14 and a bottom surface 16. Protruding connector protrusions 18 extend vertically from the top surface 14 at evenly spaced locations. The protruding connector protrusions 18 are shaped and sized to be received in concave connector receptacles (shown later) formed in the bottom surface of each toy building block 12. The concave connector receptacles are spaced apart and positioned to receive and retain the protruding connector protrusions 18. In this way, the top surface 14 of any toy building block 12 can be connected to the bottom surface 16 of any other toy building block 12.

[0021] Each toy building block 12 is made wholly or partially of a thermoplastic elastomer (TPE) material 22. The TPE material 22 can be prepared by mixing it with a plasticizer (such as mineral oil) to make the TPE material 22 softer and, if desired, more elastic. The selected TPE material 22 (whether virgin or mixed with a plasticizer) has the ability to elastically elongate at least ten percent (10%) in all directions without damage. In this way, if stretched, the size of each toy building block 12 can increase by at least 10%. Similarly, the toy building block 12 can elastically torsion without damage.

[0022] Combination Figure 1 Reference Figure 2 and Figure 3 As can be seen, at least some of the toy building blocks 12 have a body 26, which has a top surface 14, a bottom surface 16, and sidewalls 24. The top surface 14 includes a convex connector protrusion 18. The bottom surface 16 includes a concave connector receiving portion 20, which is sized to receive the convex connector protrusion 18 with an interference fit. The body 26, the convex connector protrusion 18, and the concave connector receiving portion 20 are all integrally molded from a prepared TPE material 22. Therefore, each of these surfaces and features is elastic and has the ability to be compressed, stretched, and twisted in an elastic manner. Because the convex connector protrusion 18 is made of TPE material 22, the convex connector protrusion 18 is flexible. Furthermore, because the concave connector receiving portion 20 is made of TPE material 22, the concave connector receiving portion 20 can widen when compressed. Therefore, the flexible convex connector protrusion 18 can be received by the flexible concave connector receiving portion 20 within a very wide tolerance range, as long as the applied force causes the convex connector protrusion 18 to abut against the concave connector receiving portion 20.

[0023] Combination Figure 5 and Figure 6 refer to Figure 4 As can be seen, the convex connector protrusion 18 has a cylindrical shape. The concave connector receiving portion 20 is located in the protruding shape of the convex connector protrusion 18. Furthermore, the concave connector receiving portion 20 is slightly smaller to create an interference fit between the convex connector protrusion 18 and the concave connector receiving portion 20. Both the convex connector protrusion 18 and the concave connector receiving portion 20 can be provided with a slight outward tilt angle C1, which allows the convex connector protrusion 18 to better insert and exit the concave connector receiving portion 20. However, the connection between each convex connector protrusion 18 and each concave connector receiving portion 20 can be quite robust. When the convex connector protrusion 18 is pressed into the concave connector receiving portion 20, such as... Figure 5As shown, the convex connector protrusion 18 expands slightly due to the applied compressive force. This increases the interference fit between the convex connector protrusion 18 and the concave connector receiving portion 20, forming a strong interconnection therein. This strong interconnection is maintained when various toy building blocks 12 are interconnected into a larger structure. However, when the convex connector protrusion 18 is pulled away from the concave connector receiving portion 20, such as... Figure 6 As shown, the convex connector protrusion 18 is elongated. This makes the convex connector protrusion 18 thinner and eliminates the interference fit, allowing the toy building blocks 12 to separate without damage. The result is that the connection between the toy building blocks 12 is easy to establish and secure once established, but easy to rescind if needed.

[0024] The toy building block 12 is molded from TPE material 22. The toy building block 12 can be solidly molded. However, to reduce weight and material usage, at least some of the larger toy building blocks 12 in kit 10 can be made hollow. In the larger toy building blocks 12, an internal cavity 30 can be molded into the body 26. The internal cavity 30 is disposed within the toy building block 12 between the top surface 14, the bottom surface 16, and the sidewalls 32. If the toy building block 12 is stepped or manually operated, the presence of the internal cavity 30 makes the toy building block 12 easier to compress. The internal cavity 30 can be filled with air or an inert gas. Other filling materials can also be used. The internal cavity 30 can also extend partially into the convex connector protrusion 18. In this way, the flexibility of the convex connector protrusion 18 is increased, but the pneumatic pressure maintained within the internal cavity 30 prevents the convex connector protrusion 18 from reversing when compressed.

[0025] Reference Figure 7 The stuffed toy construction block 40 is shown having the same molding construction as previously described. Therefore, the stuffed toy construction block 40 has a body 42 made of the same TPE material 22 discussed previously. In the stuffed toy construction block 40, it can be seen that an internal cavity 44 is formed within the body 42 filled with a filler material 46. The filler material 46 can take the form of a liquid, gel, and / or loose lubricating particles. In this way, the stuffed toy construction block 40 can be filled but remains free to stretch and deform. The body 42 of the stuffed toy construction block 40 is molded with sufficient wall integrity to maintain its shape while retaining the filler material 46. If the stuffed toy construction block 40 is compressed or twisted with sufficient force, the TPE material 22 can temporarily thin and expand. Once the force is removed, the stuffed toy construction block 40 returns to its initial shape. The TPE material 22 used can be translucent, allowing the filler material 46 to be observed within the body 42.

[0026] Some toy building blocks are large enough to include internal chambers. However, small or thin toy building blocks can also be included in building block kits. Figure 1 as well as Figure 8 and Figure 9 A thin toy construction block 50 is shown. The thin toy construction block 50 has a top surface 52 with a convex connector protrusion 54 and a bottom surface 56 with a concave connector receptacle 58. The top surface 52 and bottom surface 56 are part of a narrow body 57. In the thin toy construction block 50, no additional space is left in the body 57 for the space required to provide the concave connector receptacle 58 for a single enclosed internal cavity. This is due to the fact that the concave connector receptacle 58 extends from the bottom surface 56 to near the top surface 52. Although there is no chamber above the concave connector receptacle 58 for internal space, some chambers are available between the concave connector receptacles 58. To increase flexibility and reduce both material and weight, a raised portion 60 is formed in the body 57 between the concave connector receptacles 58. The raised portion 60 extends from the bottom surface 56 into the body 57 and opens along the bottom surface 56.

[0027] It should be understood that the illustrated and described embodiments of the invention are merely exemplary, and many modifications can be made to these embodiments by those skilled in the art. For example, the shape and size of the toy building blocks can be varied to meet the needs of a specific toy building block kit designed to construct a particular structure. Furthermore, the different types of toy building blocks described (such as air-filled, gel-filled, and recessed blocks) can be packaged together in groups. All these embodiments are intended to be included within the scope of the invention as defined by the appended claims.

Claims

1. A toy construction block (10), comprising: a body (26) having a top surface (14) and a bottom surface (16), wherein the body (26) is molded from a thermoplastic elastomer material that enables the body (26) to be elastically stretched; at least one male connector tab (18) extending from the top surface (14); at least one female connector receptacle (20) formed in the bottom surface (16) of the body (26); and at least one internal chamber (30) formed into the body (26), wherein the at least one internal chamber (30) is separate and distinct from the at least one female connector receptacle (20).

2. The toy construction block (10) according to claim 1, wherein The at least one internal chamber (30) is sealed within the body (26).

3. The toy construction block (10) according to claim 1, wherein The at least one internal chamber (30) extends into the at least one male connector tab (18).

4. The toy construction block (10) according to claim 1, wherein The at least one internal chamber (30) is filled with a filler material (46) selected from a liquid, a gel, and lubricious particles.

5. The toy construction block (10) according to claim 1, wherein The at least one internal chamber (30) is a single internal chamber formed within the body (26), wherein the at least one male connector tab (18) and the at least one female connector receptacle (20) are disposed on opposite sides of the internal chamber (30).

6. The toy construction block (10) according to claim 1, wherein The at least one female connector receptacle (20) comprises a plurality of female connector receptacles (20) extending into the body (26); and The at least one internal chamber (30) comprises a plurality of internal chambers (30) interposed between the plurality of female connector receptacles (20).

7. The toy construction block (10) according to claim 1, wherein The thermoplastic elastomer forming the body (26) is mixed with a plasticizing oil.

8. The toy construction block (10) according to claim 4, wherein The thermoplastic elastomer forming the body (26) is translucent to enable the filler material (46) to be seen through the thermoplastic elastomer.

9. A toy construction block kit, comprising: a plurality of interconnectable blocks (12) molded from a thermoplastic elastomer material, wherein at least some of the plurality of interconnectable blocks (12) include at least one internal chamber (30) that holds a filler material (46), wherein the filler material (46) is selected from a liquid, a gel, and lubricious particles.

10. A toy construction set according to claim 9, wherein, Each of the plurality of interconnectable blocks (12) has a body (26) having a top surface (14) and a bottom surface (16), wherein at least one male connector tab (18) extends from the top surface (14) and at least one female connector receptacle (20) is formed in the bottom surface (16) of the body (26).

11. A toy construction set according to claim 10, wherein, The at least one internal chamber (30) is separate and distinct from the at least one female connector receptacle (20).

12. The toy construction set of claim 10, wherein, The at least one internal chamber (30) extends into the at least one male connector tab (18).

13. The toy construction set of claim 10, wherein, The at least one internal chamber (30) is a single internal chamber (30) formed within the body (26), wherein the at least one male connector tab (18) and the at least one female connector receptacle (20) are disposed on opposite sides of the single internal chamber (30).

14. The toy construction set of claim 10, wherein, The at least one female connector receptacle (20) comprises a plurality of female connector receptacles (20) extending into the body (26); and The at least one internal chamber (30) comprises a plurality of internal chambers (30) interposed between the plurality of female connector receptacles (20).

15. The toy construction set of claim 9, wherein, The thermoplastic elastomer forming the body (26) is translucent to enable the filler material (46) to be seen through the thermoplastic elastomer. The at least one internal chamber (30) is a single internal chamber (30) formed within the body (26), wherein the at least one male connector tab (18) and the at least one female connector receptacle (20) are disposed on opposite sides of the single internal chamber (30). The at least one female connector receptacle (20) comprises a plurality of female connector receptacles (20) extending into the body (26); and The at least one internal chamber (30) comprises a plurality of internal chambers (30) interposed between the plurality of female connector receptacles (20). The thermoplastic elastomer forming the body (26) is translucent to enable the filler material (46) to be seen through the thermoplastic elastomer.

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