Component for installation in a structural system

Abstract

A component (2, 2') for the construction of a model of a structural system with a grid dimension is disclosed, in which connection points in a longitudinal direction (4), in a transverse direction (6) perpendicular to the longitudinal direction (4) and in a vertical direction (8) perpendicular to the longitudinal direction (4) and perpendicular to the transverse direction (6) have a predefined grid distance (18) from each other, comprising - a fastening element (14, 16) for connection with other components of the structural system in a connection direction (4, 6) perpendicular to the vertical direction (8) and - a plate (20) held above the fastening element (14, 16) in the vertical direction (8), which is bounded at least partially by a base edge (22) oriented perpendicular to the vertical direction (8) and by an edge edge (24) opposite the base edge (22), characterized in that the plate (20) is inclined at the base edge (22) to the vertical direction (8) with a base edge angle (32) and at the edge edge (24) to the vertical direction (8) with an edge edge angle (34) which is smaller than the base edge angle (32), wherein an angle of inclination (30) of the plate (20) to the vertical direction (8) between the base edge angle (32) and the edge edge angle (34) is monotonically increasing and free of inflection points.

Description

[0001] The invention relates to a component for installation in a structural system according to the preamble of claim 1.

[0002] Lego A / S has released part number 5742, a component for installation in a model of a construction system with a grid dimension in which connection points in a longitudinal direction, in a transverse direction perpendicular to the longitudinal direction, and in a vertical direction perpendicular to the longitudinal and transverse directions have a predefined grid spacing. This component comprises a fastener for connecting to other components of the construction system in a connection direction perpendicular to the vertical direction, and a plate held above the fastener (viewed vertically) which is bounded, at least in part, by a base edge oriented perpendicular to the vertical direction and an edge opposite the base edge.

[0003] DE 699 19 189 T2 discloses a toy construction kit with several building elements for constructing a model of a modular construction system with a block grid dimension. The building elements have hinged parts as connecting elements that can be detachably connected to one another. One hinged part has a substantially cylindrical, rod-shaped shaft section arranged between two flanges, and another hinged part has a claw device with two elastic fingers that elastically receive and rotatably hold the shaft section.

[0004] US Patent 2015 / 0 190 724 A1 discloses a method for manufacturing a plastic product, such as a building component for a toy construction system, and a corresponding plastic product. The product comprises a first component, manufactured by injection molding in a mold, and a second component, built up layer by layer, for example, by 3D printing. The first and second components are permanently joined together, with the first component being fully formed and ejected from the mold prior to joining. The first component may have a plate-shaped base with a surface on which coupling studs are arranged, corresponding to the grid of a toy construction system, such as that of Lego, and the second component may be applied to or printed onto this surface.

[0005] The purpose of the invention is to improve the known component.

[0006] The problem is solved by the features of the independent claim. Preferred further developments are the subject of the dependent claims.

[0007] According to one aspect of the invention, a component for cladding a model of a construction system with a grid dimension in which connection points in a longitudinal direction, in a transverse direction transverse to the longitudinal direction and in a vertical direction transverse to the longitudinal direction and transverse to the transverse direction have a predefined grid distance from each other, comprising a fastening element for connection with other components of the construction system in a connection direction perpendicular to the vertical direction and a plate held thereon, viewed in the vertical direction above the fastening element, which is bounded at least partially by a base edge oriented perpendicular to the vertical direction and by an edge opposite the base edge.According to the invention, the plate is inclined at the foot edge to the vertical direction with a foot edge angle and at the edge edge to the vertical direction with an edge edge angle which is smaller than the foot edge angle, wherein an inclination angle of the plate between the foot edge angle and the edge edge angle is monotonically increasing and free of inflection points.

[0008] The design of the component is based on the principle that the inclination angle of the plate of the aforementioned component increases and then decreases in certain areas between the base edge angle and the edge edge angle, resulting in a change in the curvature of the plate's surface. This change in curvature leads to undesirable optical effects, such as discoloration or uneven light reflections, which can impair the component's appearance. Furthermore, such a change in curvature can also generate mechanical stresses in the material surface, negatively affecting the precision and stability of the connection between components.

[0009] To solve these problems, the proposed component features a monotonically increasing angle of inclination between the base edge and the edge, free of inflection points. This achieves a uniform surface curvature, effectively preventing optical discoloration and shadowing. In particular, the surface reflects light uniformly, resulting in a more homogeneous appearance with high color fidelity.

[0010] Furthermore, the consistent slope of the inclination angle helps to minimize mechanical stresses on the surface. This improves the fit and stability of the component within the structural system. The uniform inclination also prevents material weaknesses or uneven loads from occurring at transition points, thus increasing the durability of the component.

[0011] Another advantage of the proposed design lies in the improved manufacturing quality. Since the surface of the plate is free of abrupt changes in curvature, the production process can be controlled more precisely. This reduces potential manufacturing defects and ensures that each component meets the high quality requirements.

[0012] In this way, a visually color-accurate component is created that can be precisely integrated into the construction system.

[0013] In a further development of the specified component, the base edge angle has a value of less than 5°. This results in a particularly gentle slope of the panel relative to the vertical direction, making the transition zone between the base edge and the rest of the panel surface visually and mechanically extremely uniform. This further reduces the risk of unwanted light reflections or shadows at the base edge, thus contributing to an aesthetically homogeneous surface. Furthermore, the small base edge angle allows for a more precise fit of the panel to the geometry of the structural system. This increases the component's compatibility with other elements and ensures better integration into the overall system without visible transitions or inaccuracies. At the same time, the reduced slope at the base edge minimizes the risk of mechanical stresses that could occur at steeper slopes.Another advantage lies in the improved production quality. The minimal slope at the base edge simplifies the manufacturing process, as tools and molds for producing the component need to be less complex. This increases repeatability and minimizes potential tolerance deviations, thus ensuring the high quality of the final product.

[0014] In a further development of the specified component, the edge angle has a value greater than 20°. This results in a comparatively steep inclination of the plate at the edge relative to the vertical direction, which further reduces light reflection at the edge. The steeper inclination directs the light in a specific direction, effectively minimizing optical discoloration or shadowing at the edge. Furthermore, an edge angle greater than 20° improves the stability of the edge. The increased inclination gives the plate a more robust geometry in this area, which better withstands mechanical loads and enables a more precise connection with adjacent components. This contributes to the overall solidity of the structural system and minimizes the risk of deformation or chipping at the edge. Another advantage lies in the clearly defined optical demarcation of the edge.The larger angle creates a distinct transition between the edge and the rest of the plate, enhancing the surface's aesthetic appeal. These clean contours are advantageous for complex models, as they create a more precise visual structure. Additionally, the design has a positive impact on the manufacturing process. An edge angle greater than 20° facilitates demolding the plate from the mold, since the steeper geometry places lower demands on manufacturing tolerances. This improves reproducibility and reduces potential manufacturing defects, further enhancing production quality.

[0015] In another refinement of the specified component, the increase in the plate's inclination angle per unit length in the vertical direction does not exceed 0.5% to 3.5%. Alternatively, this means that the increase in the inclination angle per unit length in the vertical direction is between 0.5° and 2° per millimeter. This limitation ensures that the plate's curvature remains particularly uniform and free of abrupt changes. This further optimizes light reflection, reduces mechanical stress, and improves manufacturing quality.

[0016] In yet another further development of the specified component, a ratio ω between a height h of the plate considered in the vertical direction and a slope of the plate at the edge corresponds to the formula w≤htan(edge ​​angle), The ratio ω is selected from a range of 14 to 24 mm, preferably between 18 and 20 mm. This further improves the optical and mechanical integration of the specified component into the grid dimensions of the construction system. At the same time, this limitation ensures that the mechanical requirements for the component are met, as the ratio ω guarantees a width-to-height ratio at which the panel remains stable without undesirable leverage effects that could lead to material failure. Finally, the specified ratio ω also offers advantages in production, since standardized dimensions facilitate manufacturing and quality control.

[0017] In a further refinement, the fastening element is designed as a sleeve with a through-opening extending in the connection direction, preferably in the form of a cross-shaped recess. This ensures defined guidance during component alignment, enabling precise positioning of the component relative to adjacent components. This is particularly important in relation to the optical alignment of the component, as even slight rotations or deviations could significantly impair the harmonious appearance of a model. The preferred cross-shaped design of the through-opening further enhances this advantage, as it not only provides defined guidance but also allows for reproducible adjustment of the component's rotational position.A cross-shaped clamping system, due to its symmetrical form, ensures that the component can only be aligned in predefined angular increments, preventing unwanted rotational movements or inaccurate alignment. This maintains the visual coherence of the entire model, and the component integrates precisely into the overall design.

[0018] In a further refinement of the specified component, the edge and base are spaced as far apart as possible in the transverse direction and approach each other with an edge and base curvature that is less than the edge curvature. This further homogenizes light reflections, minimizing optical irregularities such as shadows or discoloration. The steeper slope of the panel in the edge area, combined with the increased curvature of the edge, requires less material, as the material can be reduced in this area along its length. This targeted material saving results in a lighter panel. This is particularly advantageous for larger models, as it reduces the overall weight of the structure, positively impacting handling and stability.Since less material is required to manufacture the component, production costs can be reduced. This is an economic advantage, particularly important in mass production. Furthermore, the reduced amount of material also lowers energy consumption during the manufacturing process. Despite the material savings, mechanical stability is maintained because the forces are distributed evenly along the panel. The curved base edge helps ensure structural strength in the base area, while the straight, steeper edge edge allows for efficient material utilization.

[0019] In a preferred refinement of the specified component, the curvature of the base edge is zero, meaning the base edge is straight. This significantly simplifies manufacturing, as it can be produced with less complex tools and molds. This results in lower manufacturing costs and higher production precision, since simple geometries exhibit fewer tolerance deviations. Furthermore, a straight base edge provides a more stable foundation for attaching the plate to the rest of the structure. The larger contact area ensures more even force transmission and increases the mechanical stability of the entire component, especially in larger models where stability and load-bearing capacity are crucial. Another advantage lies in optimized material utilization.The straight edge of the base allows for more efficient material use, as no additional reinforcements or material build-ups are required to ensure stability. This reduces material consumption and contributes to resource-efficient production. At the same time, the straight edge creates a clear visual separation between the base of the component and the inclined plate. This reduces gaps, as the transitions between the components appear cleaner and more precise. Finally, the straight edge increases the component's compatibility with other elements of the construction system, as it adapts better to straight or flat surfaces, thereby increasing assembly flexibility.

[0020] In a specific further development of the specified component, the edge, viewed longitudinally, slopes monotonously, preferably with a strictly monotonous gradient, towards the base edge. This prevents irregularities in the reflection of light on the surface. The uniform decrease in the longitudinal direction ensures that light is distributed homogeneously, minimizing discoloration or disruptive shadowing. The sloping edge also allows for a targeted distribution of material along the plate. Because the slope is uniform, the component's weight is reduced without compromising its stability. This leads to more efficient material use and increases mechanical strength, as no weak points arise from abruptly changing geometries. The sloping edge facilitates the integration of the component into models, as it provides a natural transition shape.Especially with complex structures or sloping surfaces, a monotonous taper has a positive effect on fit and appearance. The plate integrates cleanly into the construction system and creates a uniform surface. Furthermore, a monotonous or strictly monotonous taper at the edge is easier to manufacture than more complex or variable geometries. The uniform shape reduces tooling requirements and minimizes manufacturing tolerances. This allows for more consistent component production and lowers manufacturing costs. In certain scenarios, such as models intended to simulate aerodynamic properties, a strictly monotonous taper is advantageous because the flowing shape reduces drag and improves the model's behavior in dynamic applications.

[0021] In a particularly preferred embodiment, the component includes a stabilizing element that has an angled cross-section in the longitudinal direction and supports the plate from its underside in the vertical direction. The angled design effectively transfers the load acting on the plate to the support element. This prevents potential deflection or deformation of the plate, even under higher loads, and ensures a uniform force distribution. Furthermore, the stabilizing element increases the overall stiffness of the component, which is particularly advantageous for larger models or in areas subject to high stress. The support of the plate from the underside minimizes material stresses and ensures that the component retains its shape even under repeated loading.At the same time, the component's visual appearance is preserved, as the stabilizing element is integrated into the underside and thus does not affect the visible surfaces of the panel. Additionally, the angled design of the stabilizing element contributes to efficient material use. This shape enables high stability with minimal material expenditure, reducing both production costs and the component's weight. Overall, this element significantly improves the component's functionality and durability without compromising its aesthetic or technical integration into the overall system.

[0022] The properties, features, and advantages of this invention described above, as well as the manner in which they are achieved, will become clearer in connection with the following description of the exemplary embodiments, which are explained in more detail in conjunction with the drawings. The drawings show: Fig. 1 a view of a component according to a first embodiment from a first perspective, Fig. 2 a view of the component of the Fig. 1 from a second perspective, and Fig. 3 a perspective view of a component according to a second embodiment.

[0023] In the figures, identical technical elements are labelled with the same reference symbols and described only once. The figures are purely schematic and, above all, do not represent the actual geometric relationships.

[0024] It will be on Fig. 1 and Fig. Reference is made to Figure 2, which shows a view of a component 2 according to a first embodiment from two different perspectives. The component 2 is considered below in a space spanned by a longitudinal direction 4, a transverse direction 6 perpendicular to the longitudinal direction 4, and a vertical direction 8 perpendicular to the longitudinal direction 4 and perpendicular to the transverse direction 6.

[0025] Component 2, viewed in the vertical direction 8, has five fasteners of different designs on its underside 12, four of which are arranged in a building block grid. A building block grid is a systematic dimensional scheme that standardizes the arrangement and spacing of fasteners such as studs, tubes, or other connecting elements on a building block. This standardization allows building blocks to be connected precisely, modular structures to be created, and systems to be scaled as needed. Various building block grids exist, known on the market under names such as Standard, Diamond, and Mini.The most well-known building block grid, called Standard, was defined by the company Lego A / S and has a grid dimension in which the individual fasteners have a maximum width of 4.8mm and a distance of 8mm from each other, although the following explanations are not limited to this.

[0026] Two of the four fastening elements in the building block grid are designed as shaft receptacles 14, while the other two are designed as axle receptacles 16. The shaft receptacles 14 are characterized in that they can accommodate a shaft or a stud of another building block, i.e., a mechanical component that can rotate within the shaft receptacle 14, depending on whether the shaft receptacle 14 accommodates the shaft as an interference fit or a clearance fit. In contrast, the axle receptacles 16 are characterized in that they can accommodate axles, i.e., mechanical components that cannot rotate within the axle receptacle 16, regardless of the fit. In the present embodiment, the axle receptacles 16 are designed as cross receptacles.The four fastening elements 14, 16 engage their respective connecting partner, i.e. the stud, the shaft or the axle, in a specific connection direction (in . Fig. 1 and Fig. 2 also either in the longitudinal direction 4 or in the transverse direction 6) and are further characterized in the block block grid by the fact that they have a uniform grid spacing 18 from each other in all four spatial directions 4 to 8, which in the Fig. 1 and Fig. 2 is referenced only in one place each.

[0027] The fifth fastening element 19 in the Fig. 1 and Fig. In contrast, 2 is defined independently of the grid dimension and is intended, for example according to the Poka-Yoke principle, to only allow certain components in the construction system to be connected, which have an analogous fastening element outside the grid dimension. Otherwise, the fifth fastening element 19 functions in the same way as the other four fastening elements in the Fig. 1 and Fig. 2.

[0028] Viewed in the vertical direction 8 above the fastening elements 14, 16, and 19, a plate 22 is held to these elements and is bounded by several edges. The first of these edges is referred to below as the base edge 22, is essentially oriented in the longitudinal direction 4, and bounds the plate 20 on its front side as viewed in the transverse direction 6. Opposite the base edge 22 in the transverse direction 6, an edge edge 24 is arranged. On its rear side as viewed in the longitudinal direction 4, the plate 20 is bounded by a further edge called the end edge 26, while opposite this, on its front side as viewed in the longitudinal direction 4, the plate 20 is bounded by a pointed edge 28. These edges 22 to 28 are only present as examples in this embodiment and do not necessarily all have to be present together. An embodiment with, for example, only a base edge 22 and an edge edge 24 is also conceivable.Edges 22 to 28 do not need to completely enclose the plate. This is in the design of the... Fig. 1 and Fig. 2 at the location of the fastening elements 14, 16 is illustrated.

[0029] The plate 20 is inclined at a variable angle 30° to the vertical direction 8 on the upper surface 10 of component 2. The angle 30° is defined below as the angle between the mathematical gradient, i.e., the direction of the steepest slope of plate 20 on the upper surface 10 of component 2, and the vertical direction 8. Since the vertical direction 8 is constant, this means that the gradient of plate 20 on the upper surface 10 of component 2 changes, specifically in the manner described below.

[0030] At the base edge 22, the angle of inclination 30 has a value that will be referred to below as the base edge angle 32, while the angle of inclination 30 at the edge edge 24 will be referred to as the edge edge angle 34. These two angle values ​​32 and 34 are chosen such that the angle of inclination 30 becomes increasingly steep from the base edge angle 32 to the edge edge angle 34, meaning that the gradient is strictly monotonically increasing, so that the angle of inclination 30 has no inflection points. This has the crucial advantage that component 2 is significantly more color-accurate than, for example, the comparable component from Lego A / S, which is sold on the market under part number 5742, because component 2 does not exhibit any change in the curvature of the surface of plate 20 facing the top 10, thus avoiding color-distorting, uneven light reflections and shadows.

[0031] The entire component is designed such that, in a cross-section viewed in the longitudinal direction, it has a width of three grid spacings 18 in the transverse direction 6 and a height of two grid spacings 18 in the vertical direction 8, thus fitting into the grid of a conventional 3x2 interlocking building block in this cross-section. For the smoothest possible alignment of the component on the fastening elements 14, 16 within the interlocking building block grid, a value of 0° was chosen for the base edge angle 32. Larger values ​​can also be chosen in principle; however, it has been shown that if a value greater than 5° is chosen for the base edge angle 32, there is insufficient angular leeway along the path of the plate 20 in the transverse direction 6 to implement the fundamental inventive concept of color fidelity.Various values ​​can also be chosen for the edge angle 34; however, the edge angle 34 should not be too large to avoid unintended shadowing. In practice, an edge angle 34 of at least 20° has proven effective and is set to 40° in this particular design.

[0032] As an additional dimensioning criterion, the edge angle 34 can also be selected depending on the height: w≤htan(edge ​​angle) Here, h corresponds to the height of the plate 20 in the vertical direction 8, and ω is the ratio between the height h of the plate 20 and the tangent of the edge angle 34. That is, the larger the plate 20 is in the vertical direction 8, the larger the edge angle 34 should be chosen to ensure the monotonous behavior of the inclination angle 30 in the transverse direction, thus maintaining sufficient color fidelity for the viewer. In the present embodiment, the ratio ω is therefore approximately 18.6 mm.

[0033] Now, an optimal alignment of the base edge 22 and the edge edge 24 will be explained. The base edge 22 should be aligned as straight as possible in the longitudinal direction to avoid gaps when installed with other components of the construction system. In contrast, the edge edge 24 should run towards the base edge 22 from a maximum distance 36 in the longitudinal direction 4. This has the advantage that component 2 can be manufactured with significantly less material than the aforementioned component 5742 from Lego A / S.

[0034] To stabilize the plate, it can be supported against one of the fastening elements 16 by a stabilizing element 37. This stabilizing element 37 is an angled wall with a cross-section extending in the longitudinal direction 4, which initially angles in the transverse direction 6 from the fastening element 16 towards the vertical direction 8 and supports the plate 20 from below in the vertical direction 8. This wall can be further supported by a retaining wall 38 extending transversely to the longitudinal direction 4 for additional mechanical stabilization of the component 2.

[0035] The stabilizing element 37 incorporates a special fastening element 19 that deviates from the grid dimension, resulting in a more compact design.

[0036] It will be on Fig. 3 Reference is made to Figure 3, which shows a perspective view of a component 2' according to a second embodiment.

[0037] The elements of component 2 of the first embodiment, which are also implemented in the component of the second embodiment, are provided with the same reference numerals and will not be explained again for the sake of brevity.

[0038] In the present embodiment, in addition to the variable inclination angle 30 of the plate 20 on the upper surface 10 of the component 2' in the transverse direction 6, a variable inclination angle 40 of the plate 20 on the upper surface 10 of the component 2' is formed in the longitudinal direction 4. This additional variable inclination angle 40 in the longitudinal direction 4 satisfies the same conditions as the variable inclination angle 30 in the transverse direction 6, with the sole exception that the additional variable inclination angle 40 in the longitudinal direction 4 is not increasing with the longitudinal direction 4 but decreasing. However, this is merely a matter of the choice of coordinate system and has no influence on the underlying concept of implementing the inclination angles monotonically without inflection points.

[0039] The variable inclination angle 40 in the longitudinal direction 4 can easily be implemented in component 2 according to the first embodiment, while, conversely, component 2' according to the second embodiment can also be individually extended to include all the features of the first embodiment.

Claims

[1] Component (2, 2') for constructing a model of a structural system with a grid dimension in which connection points in a longitudinal direction (4), in a transverse direction (6) perpendicular to the longitudinal direction (4) and in a vertical direction (8) perpendicular to the longitudinal direction (4) and perpendicular to the transverse direction (6) have a predefined grid distance (18) from each other, comprising - a fastening element (14, 16) for connection with other components of the structural system in a connection direction (4, 6) perpendicular to the vertical direction (8) and - a plate (20) held above the fastening element (14, 16) as seen in the vertical direction (8), which is bounded at least in part by a foot edge (22) oriented perpendicular to the vertical direction (8) and by an edge edge (24) opposite the foot edge (22), characterized by, that the plate (20) is inclined at the foot edge (22) to the height direction (8) with a foot edge angle (32) and at the edge edge (24) to the height direction (8) with an edge edge angle (34) which is smaller than the foot edge angle (32), wherein an inclination angle (30) of the plate (20) to the height direction (8) between the foot edge angle (32) and the edge edge angle (34) is monotonically increasing and free of inflection points. [2] Component (2, 2') according to claim 1, wherein the foot edge angle (32) has a value between 0° and 5°. [3] Component (2, 2') according to claim 1 or 2, wherein the edge angle (34) has a value between 20° and 40°. [4] Component (2, 2') according to one of the preceding claims, an increase in the inclination angle (30) of the plate (20) per unit length of the plate (20) in the vertical direction (8) does not exceed 0.5% to 3.5%. [5] Component (2, 2') according to one of the preceding claims, wherein a ratio ω between a height h of the plate (20) considered in the vertical direction (8) and the edge angle 34 corresponds to the following formula: w≤htan(edge ​​angle), wherein the ratio ω is selected from a range between 14 and 24 mm, preferably between 18 and 20 mm. [6] Component (2, 2') according to one of the preceding claims, wherein the fastening element (16) is designed as a sleeve with a through-opening extending in the connection direction (4, 6), preferably in the form of a cross-shaped recess. [7] Component (2) according to one of the preceding claims, wherein the edge (24) and the foot (22) have a maximum distance (36) from each other in the transverse direction (6) and approach each other with an edge curvature and a foot curvature smaller than the edge curvature. [8] Component (2) according to claim 7, wherein the foot edge curvature is zero. [9] Component (2) according to one of the preceding claims, wherein the edge edge (24) is monotonously, preferably strictly monotonically, decreasing in the longitudinal direction (4) towards the foot edge (22). [10] Component (2) according to one of the preceding claims, comprising a stabilizing element (37) which is angularly formed in a cross-section seen in the longitudinal direction (4) and supports the plate (20) from the fastening element (14, 16) from a bottom side (12) seen in the vertical direction (8).

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