Three-dimensional plush figure and puzzle system

Abstract

A three-dimensional puzzle system includes plush or otherwise stuffed pieces configured to interlock via complementary slots. A body piece defines at least one body slot extending inward from an outer perimeter and has a first thickness. An appendage piece defines at least one appendage slot extending inward from an outer perimeter and has a second thickness. The body slot has a width at least the second thickness and the appendage slot has a width at least the first thickness. During assembly, the appendage piece is oriented transverse to the body piece, the slots are aligned, and the pieces are threaded into one another to form a stable three-dimensional figure. The figure is capable of disassembly into pieces that may be stored substantially flat or compactly stacked for shipping or storage.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 762,731, filed February 25, 2025, the entire contents of which are incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to plush figures, toys and puzzles. More particularly, the present disclosure relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, robots, vehicles, buildings) from interconnectable plush or other stuffed pieces.BACKGROUND

[0003] Conventional jigsaw and construction puzzles are typically planar and assembled into a two-dimensional image or a rigid three-dimensional form. Plush toys are typically provided as fully assembled figures. There remains a need for construction-style puzzles that provide a soft, plush tactile experience while enabling repeatable assembly into a stable three-dimensional figure.SUMMARY

[0004] A three-dimensional puzzle system is disclosed in which multiple plush (or otherwise stuffed) pieces are configured to interlock via complementary slots. In an example, a body or core piece defines one or more body slots extending inward from an outer perimeter or edge thereof. One or more appendage pieces each define one or more appendage slots extending inward from an outer perimeter or edge thereof. The body slot is sized to receive a portion of an appendage piece, and the appendage slot is sized to receive a portion of the body piece. During assembly, the appendage piece is oriented transverse (e.g., at an angle or orthogonal) to the body piece and the slots are aligned such that the pieces are threaded or otherwise overlapped into one another to form a stable three-dimensional figure.

[0005] In some examples, one or more pieces include a rigid or semi-rigid core (e.g., cardboard or pressboard), optionally a cushioning layer (e.g., foam), and an outer plush layer (e.g., plush fabric, velour, velvet, felt, artificial fur). The slots can have equal or varying depths and can be distributed around the perimeter to accept multiple appendages, allowing formation of different figures using a common body piece.

[0006] Because the pieces are coupled using slots and may be separated without tools, the assembled three-dimensional figure may be readily disassembled into individual pieces for storage. In an unassembled state, the pieces can be stored substantially flat and / or compactly stacked, thereby reducing the volume required for shipping, merchandising, travel, and home storage.

[0007] In some embodiments, the system supports mix-and-match construction. For example, a body piece may be configured as a core that is attachable to one or more outer body pieces (e.g., coverings, shells, or skins) having different appearances, colors, patterns, or characters. Additionally or alternatively, appendage pieces from different kits or different figures may be interchangeably coupled to a selected body piece, allowing a user to create unique or customized three-dimensional plush figures according to the child’s desire or imagination.

[0008] According to an aspect of the disclosure, a three-dimensional puzzle system is provided and includes a body piece having an outer perimeter and defining at least one body slot extending inward from the outer perimeter; and an appendage piece having an outer perimeter and defining at least one appendage slot extending inward from the outer perimeter. The body piece has a first thickness and the appendage piece has a second thickness. A width of the at least one body slot is at least the second thickness and a width of the at least one appendage slot is at least the first thickness. The body piece and the appendage piece are configured to be assembled by orienting the appendage piece transverse to the body piece, aligning the at least one body slot with the at least one appendage slot, and threading the body piece and the appendage piece into one another such that a portion of the body piece is received within the at least one appendage slot and a portion of the appendage piece is received within the at least one body slot to form a three-dimensional figure. The body piece and the appendage piece are formed at least in part of a compressible and resilient material.

[0009] The appendage piece may be configured to be oriented substantially orthogonal to the body piece during said threading.

[0010] The three-dimensional puzzle system may further include a plurality of appendage pieces, each appendage piece including a respective appendage slot configured to interlock with a corresponding body slot of the body piece.

[0011] The body piece may define a plurality of body slots distributed around the outer perimeter of the body piece.

[0012] At least one of the body slot or the appendage slot may have a depth selected to position an exterior surface of the body piece substantially flush with an exterior surface of the appendage piece when assembled.

[0013] At least one of the body piece or the appendage piece may comprise a rigid or semi-rigid core layer and an outer plush layer covering the core layer.

[0014] The at least one of the body piece or the appendage piece may further comprise a cushioning layer disposed between the rigid or semi-rigid core layer and the outer plush layer.

[0015] The appendage piece may comprise an outer textile layer having at least one of plush, velour, velvet, felt, artificial fur, or flocking.

[0016] At least one of the body piece or the appendage piece may be non-planar.

[0017] The body piece and the appendage piece may be configured to be retained in an assembled state by a friction fit between surfaces of the slots and surfaces of received portions of the pieces.

[0018] The body piece and the appendage piece may be selectively capable of disassembly by reversing the threading such that the pieces separate into an unassembled state.

[0019] In the unassembled state, at least a plurality of the pieces may be substantially planar and are configured to be stored substantially flat or stacked to reduce storage volume.

[0020] The pieces are packaged for shipment in the unassembled state in a compact stacked arrangement.

[0021] The three-dimensional puzzle system may further comprise an outer body piece configured to be removably coupled to the body piece to change an appearance of the three-dimensional figure.

[0022] The outer body piece may be coupled to the body piece using a selectively closable connection.

[0023] The appendage piece may be interchangeably couplable with the body piece and at least one additional appendage piece from a different three-dimensional plush figure kit based on compatible slot dimensions.

[0024] The appendage piece may be flexible along at least a portion of a length thereof, and wherein the appendage piece includes a wire integrated into at least a portion of the length thereof.

[0025] The body piece and each appendage piece may be joined via a half-lap joint between the body piece and each appendage piece.

[0026] According to another aspect of the disclosure, a method of assembling and storing a three-dimensional plush puzzle is provided. The method includes assembling a body piece and an appendage piece by orienting the appendage piece transverse to the body piece, aligning a body slot with an appendage slot, and threading the body piece and the appendage piece into one another to form a three-dimensional figure; disassembling the three-dimensional figure by reversing the threading to separate the body piece and the appendage piece; and storing the separated pieces in a substantially flat or compact stacked arrangement for shipping or space-saving storage.

[0027] The method may further comprise forming a customized figure by interchanging at least one of (a) an outer body piece coupled to the body piece or (ii) an appendage piece selected from a set associated with a different three-dimensional plush figure.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings illustrate embodiments of the disclosed subject matter. In the drawings:

[0029] FIG. 1 is a perspective view of an example three-dimensional plush puzzle system assembled as an animal FIGURE(rabbit example).

[0030] FIG. 1A is a cross-sectional view as taken through 1A-1A of FIG. 1.

[0031] FIG. 2 is a perspective view of example pieces of the three-dimensional plush puzzle system of FIG. 1 shown in a disassembled state.

[0032] FIG. 3 is a perspective view of a pair of example pieces of the three-dimensional plush puzzle system of FIG. 1, and further illustrating example slot widths and piece thicknesses.

[0033] FIG. 4 is an assembled view for a cat configuration of the three-dimensional plush puzzle system of the present disclosure.

[0034] FIG. 5 illustrates example pattern pieces for the cat configuration of the three-dimensional plush puzzle system of FIG. 4.

[0035] FIG. 6 is an assembled view for an elephant configuration of the three-dimensional plush puzzle system of the present disclosure.

[0036] FIG. 7 illustrates example pattern pieces for the elephant configuration of the three-dimensional plush puzzle system of FIG. 6.

[0037] FIG. 8 illustrates an assembled view for a horse configuration of the three-dimensional plush puzzle system of the present disclosure.

[0038] FIG. 9 illustrates an assembled view for a pig configuration of the three-dimensional plush puzzle system of the present disclosure.

[0039] FIG. 10 illustrates an assembled view for a dog configuration of the three-dimensional plush puzzle system of the present disclosure.DETAILED DESCRIPTION

[0040] The present application relates to puzzles made of plush. More specifically, the present application relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, aliens, robots, vehicles, buildings) wherein each piece of the puzzle is made of plush or other stuffed construction and the pieces are joined to one another in a threaded or dovetail-like or half-lap joint manner.

[0041] As illustrated in FIGS. 1-2, the three-dimensional plush puzzle system is generally designated by reference character 100. When assembled, the three-dimensional plush puzzle system 100 forms a three-dimensional figure such as an animal (e.g., a rabbit, dog, cat, elephant, horse, pig), although any other figure or object is contemplated, including dolls, creatures, aliens, robots, buildings, castles, vehicles, cars, planes, and boats.Puzzle Pieces

[0042] Each three-dimensional plush puzzle system 100 includes a body or core piece 110 and at least one appendage piece 120. The body piece 110 may constitute a torso or central support of the figure, and the appendage piece(s) 120 may constitute arms, legs, ears, tails, trunks, faces, heads, wings, fins, or other features.

[0043] The body piece 110 defines an outer perimeter 110a and one or more body slots 112 projecting or extending into the body piece 110 from the outer perimeter 110a. The body piece 110 has a thickness “T1”, and each body slot 112 has a width “W1”. The body slot(s) 112 may have equal or varying depths extending into the body piece 110 depending on the size and shape of the appendage piece(s) 120 to be received.

[0044] Each appendage piece 120 defines an outer perimeter 120a and one or more appendage slots 122 extending or projecting into the appendage piece 120 from the outer perimeter 120a. Each appendage piece 120 has a thickness “T2”, and each appendage slot 122 has a width “W2”. The appendage slot(s) 122 may have equal or varying depths extending into the appendage piece 120 depending on the intended connection to the body piece 110 or to another appendage piece.

[0045] Although the body piece 110 and appendage piece(s) 120 may be planar, it is also contemplated that one or more pieces may be non-planar or curved to more accurately represent an intended figure or to increase stability in the assembled configuration.

[0046] The slots, namely, body slots 112 and appendage slots 122, may extend along an axis “X” which is orthogonally angled into the respective body piece 110 or appendage piece 120 with respect to a plane or chord “P1” (see FIG. 5) extending perpendicular to the respective outer perimeter 110a, 120a. Alternatively, the slots, namely, body slots 112 and appendage slots 122, may extending along an axis “Y” which is non-orthogonally angled into the respective body piece 110 or appendage piece 120 with respect to a plane or chord “P1” extending perpendicular to the respective outer perimeter 110a, 120a.

[0047] In embodiments, the appendage pieces 120 may be flexible along a portion or substantially along an entire length thereof, and may include an integrated wire 120b (see FIGS. 4-5) to form a tail, and to permit the tail to be curved or shaped as desired.Slot-Based Interlocking Connection

[0048] In accordance with the present disclosure, the width “W1” of the body slot(s) 112 is substantially equal to or larger than the thickness “T2” of the appendage piece(s) 120, and the width “W2” of the appendage slot(s) 122 is substantially equal to or larger than the thickness “T1” of the body piece 110 to which the appendage piece 120 is to be attached. In this manner, a body slot 112 may receive a portion of an appendage piece 120, and an appendage slot 122 may receive a portion of the body piece 110 when the pieces are joined, in the manner of a lap joint or half-lap joint.

[0049] More specifically, the body piece 110 defines a body plane and each appendage piece 120 defines an appendage plane. During connection of an appendage piece 120 to the body piece 110, the appendage piece 120 is oriented such that the appendage plane is transverse (e.g., orthogonal) to the body plane. Once so oriented, a body slot 112 is aligned with an appendage slot 122 and the body piece 110 and appendage piece 120 are fed into or threaded into one another such that a portion of the body piece 110 is received into the appendage slot 122 and a portion of the appendage piece 120 is received into the body slot 112, in the manner of a lap joint or half-lap joint.

[0050] In some embodiments, the body slots 112 and the appendage slots 122 are sized to create a friction fit that retains the pieces in an assembled state during normal play. Additionally or alternatively, the system 100 may include a secondary retention feature, such as a hook-and-loop patch, snap, button, magnet, or tether, positioned adjacent a slot to inhibit unintended separation while still permitting disassembly.Materials and Construction

[0051] One or more of the body piece 110 and appendage pieces 120 may be fabricated from plush, smocking, velour, velvet, felt, artificial fur, flocking, foam, or the like. In an embodiment, the body piece 110 and / or the appendage piece(s) 120 are constructed entirely or at least in part of a compressible and resilient material (e.g., foam). In an example construction, as illustrated in FIG. 1A, a piece (e.g., body piece 110 or appendage piece 120) includes a rigid or semi-rigid core “C” (see FIG. 2) made of a material (e.g., cardboard, pressboard, plastic sheet, or fiberboard) that provides structural support. The core “C” may be covered by a cushioning or outer layer “CL” (e.g., foam) and further covered by an outer textile or plush layer “PL” (e.g., plush, velour, velvet, artificial fur).

[0052] In some examples, as illustrated in FIG. 1A, one or more pieces include a rigid or semi-rigid core “C” (e.g., cardboard or pressboard), optionally a cushioning layer “CL” (e.g., foam), and an outer plush layer “PL” (e.g., plush fabric, velour, velvet, felt, artificial fur).

[0053] The body or appendage piece perimeter 110a, 120a may be finished using stitching, binding tape, heat sealing, adhesive, or other edge finishing techniques. The edges of slots 112, 122 may be reinforced using stitching, binding, lamination, grommets, or localized stiffeners to reduce wear and maintain dimensional tolerances.Kits and Variations

[0054] The system 100 may be provided as a kit including a plurality of pieces that can be assembled into a selected figure. In some embodiments, different sets of appendage pieces 120 can be interchangeably coupled to a common body piece 110 to form different figures(e.g., different animals) or different poses of the same figure.

[0055] In some embodiments, the kit includes multiple sets of appendage pieces configured as different animals or characters. For example, FIGS. 3-8 illustrate non-limiting example configurations (cat, dog, elephant, horse, pig) that share common interlocking principles while using different body profiles and appendage profiles.

[0056] In these examples, a body piece includes multiple body slots positioned around the perimeter at locations corresponding to at least one of front legs, back legs, ears, tail, neck, or a face piece. Appendage pieces (e.g., legs, ears, tail, trunk, face) each include one or more appendage slots that engage a corresponding body slot, or other appendage pieces.

[0057] The example templates of FIGS. 3-8 further illustrate that different appendage categories may be shaped and slotted differently. For instance, a leg piece may define a central appendage slot sized to receive a portion of the body piece, while an ear piece may define a shorter appendage slot positioned near a base region of the ear piece. A face piece may include multiple appendage slots to receive portions of multiple other pieces and / or to couple to a body slot.

[0058] In some embodiments, at least one appendage piece includes an internal bendable member 230 (e.g., a wire) that permits the appendage piece to be posed or curved. For example, FIGS. 3, 7, and 8 illustrate a tail piece that may include a bendable wire to allow a user to curve the tail in different directions while the tail remains coupled to the body piece.Disassembly and Compact Storage

[0059] In use, the assembled three-dimensional plush figure may be disassembled by reversing the threading operation described above, thereby separating the appendage piece(s) from the body piece. Because the pieces may be generally planar and include slots extending inward from the perimeter, the pieces may be stored in an unassembled state substantially flat. In some embodiments, the pieces are stacked, nested, or otherwise arranged in a compact bundle for shipping and / or for space-saving storage in a drawer, backpack, suitcase, or toy bin. This flat or compact storage configuration can reduce packaging size and shipping volume relative to a pre-assembled plush toy.

[0060] Interchangeable Parts and Custom Figures. In some embodiments, one or more pieces are standardized such that components are interchangeable across different figure themes. For example, a body piece may function as a core that couples to one or more outer body pieces (e.g., a removable outer body covering, sleeve, shell, or skin) having different characters, textures, colors, and / or printed indicia, while maintaining compatible slot locations. In some embodiments, an outer body piece is coupled to the body / core piece using one or more slots, hook-and-loop patches, snaps, magnets, or other releasable fasteners.

[0061] Additionally or alternatively, appendage pieces from different three-dimensional plush figures(e.g., from different kits) may share common slot dimensions and / or standardized slot locations and can therefore be coupled to a selected body piece. In this manner, a child may combine ears, tails, limbs, faces, wings, and / or accessories from different sets to create hybrid or imaginative characters. In some embodiments, the kit includes a plurality of appendage pieces having multiple different aesthetic designs but compatible connection geometry, thereby encouraging creative customization while preserving stable interlocking assembly.

Examples

Embodiment Construction

[0040]The present application relates to puzzles made of plush. More specifically, the present application relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, aliens, robots, vehicles, buildings) wherein each piece of the puzzle is made of plush or other stuffed construction and the pieces are joined to one another in a threaded or dovetail-like or half-lap joint manner.

[0041]As illustrated in FIGS. 1-2, the three-dimensional plush puzzle system is generally designated by reference character 100. When assembled, the three-dimensional plush puzzle system 100 forms a three-dimensional figure such as an animal (e.g., a rabbit, dog, cat, elephant, horse, pig), although any other figure or object is contemplated, including dolls, creatures, aliens, robots, buildings, castles, vehicles, cars, planes, and boats.

Puzzle Pieces

[0042]Each three-dimensional plush puzzle system 100 includes a body or core piece 110 and at least one appendage piec...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 762,731, filed February 25, 2025, the entire contents of which are incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to plush figures, toys and puzzles. More particularly, the present disclosure relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, robots, vehicles, buildings) from interconnectable plush or other stuffed pieces.BACKGROUND

[0003] Conventional jigsaw and construction puzzles are typically planar and assembled into a two-dimensional image or a rigid three-dimensional form. Plush toys are typically provided as fully assembled figures. There remains a need for construction-style puzzles that provide a soft, plush tactile experience while enabling repeatable assembly into a stable three-dimensional figure.SUMMARY

[0004] A three-dimensional puzzle system is disclosed in which multiple plush (or otherwise stuffed) pieces are configured to interlock via complementary slots. In an example, a body or core piece defines one or more body slots extending inward from an outer perimeter or edge thereof. One or more appendage pieces each define one or more appendage slots extending inward from an outer perimeter or edge thereof. The body slot is sized to receive a portion of an appendage piece, and the appendage slot is sized to receive a portion of the body piece. During assembly, the appendage piece is oriented transverse (e.g., at an angle or orthogonal) to the body piece and the slots are aligned such that the pieces are threaded or otherwise overlapped into one another to form a stable three-dimensional figure.

[0005] In some examples, one or more pieces include a rigid or semi-rigid core (e.g., cardboard or pressboard), optionally a cushioning layer (e.g., foam), and an outer plush layer (e.g., plush fabric, velour, velvet, felt, artificial fur). The slots can have equal or varying depths and can be distributed around the perimeter to accept multiple appendages, allowing formation of different figures using a common body piece.

[0006] Because the pieces are coupled using slots and may be separated without tools, the assembled three-dimensional figure may be readily disassembled into individual pieces for storage. In an unassembled state, the pieces can be stored substantially flat and / or compactly stacked, thereby reducing the volume required for shipping, merchandising, travel, and home storage.

[0007] In some embodiments, the system supports mix-and-match construction. For example, a body piece may be configured as a core that is attachable to one or more outer body pieces (e.g., coverings, shells, or skins) having different appearances, colors, patterns, or characters. Additionally or alternatively, appendage pieces from different kits or different figures may be interchangeably coupled to a selected body piece, allowing a user to create unique or customized three-dimensional plush figures according to the child’s desire or imagination.

[0008] According to an aspect of the disclosure, a three-dimensional puzzle system is provided and includes a body piece having an outer perimeter and defining at least one body slot extending inward from the outer perimeter; and an appendage piece having an outer perimeter and defining at least one appendage slot extending inward from the outer perimeter. The body piece has a first thickness and the appendage piece has a second thickness. A width of the at least one body slot is at least the second thickness and a width of the at least one appendage slot is at least the first thickness. The body piece and the appendage piece are configured to be assembled by orienting the appendage piece transverse to the body piece, aligning the at least one body slot with the at least one appendage slot, and threading the body piece and the appendage piece into one another such that a portion of the body piece is received within the at least one appendage slot and a portion of the appendage piece is received within the at least one body slot to form a three-dimensional figure. The body piece and the appendage piece are formed at least in part of a compressible and resilient material.

[0009] The appendage piece may be configured to be oriented substantially orthogonal to the body piece during said threading.

[0010] The three-dimensional puzzle system may further include a plurality of appendage pieces, each appendage piece including a respective appendage slot configured to interlock with a corresponding body slot of the body piece.

[0011] The body piece may define a plurality of body slots distributed around the outer perimeter of the body piece.

[0012] At least one of the body slot or the appendage slot may have a depth selected to position an exterior surface of the body piece substantially flush with an exterior surface of the appendage piece when assembled.

[0013] At least one of the body piece or the appendage piece may comprise a rigid or semi-rigid core layer and an outer plush layer covering the core layer.

[0014] The at least one of the body piece or the appendage piece may further comprise a cushioning layer disposed between the rigid or semi-rigid core layer and the outer plush layer.

[0015] The appendage piece may comprise an outer textile layer having at least one of plush, velour, velvet, felt, artificial fur, or flocking.

[0016] At least one of the body piece or the appendage piece may be non-planar.

[0017] The body piece and the appendage piece may be configured to be retained in an assembled state by a friction fit between surfaces of the slots and surfaces of received portions of the pieces.

[0018] The body piece and the appendage piece may be selectively capable of disassembly by reversing the threading such that the pieces separate into an unassembled state.

[0019] In the unassembled state, at least a plurality of the pieces may be substantially planar and are configured to be stored substantially flat or stacked to reduce storage volume.

[0020] The pieces are packaged for shipment in the unassembled state in a compact stacked arrangement.

[0021] The three-dimensional puzzle system may further comprise an outer body piece configured to be removably coupled to the body piece to change an appearance of the three-dimensional figure.

[0022] The outer body piece may be coupled to the body piece using a selectively closable connection.

[0023] The appendage piece may be interchangeably couplable with the body piece and at least one additional appendage piece from a different three-dimensional plush figure kit based on compatible slot dimensions.

[0024] The appendage piece may be flexible along at least a portion of a length thereof, and wherein the appendage piece includes a wire integrated into at least a portion of the length thereof.

[0025] The body piece and each appendage piece may be joined via a half-lap joint between the body piece and each appendage piece.

[0026] According to another aspect of the disclosure, a method of assembling and storing a three-dimensional plush puzzle is provided. The method includes assembling a body piece and an appendage piece by orienting the appendage piece transverse to the body piece, aligning a body slot with an appendage slot, and threading the body piece and the appendage piece into one another to form a three-dimensional figure; disassembling the three-dimensional figure by reversing the threading to separate the body piece and the appendage piece; and storing the separated pieces in a substantially flat or compact stacked arrangement for shipping or space-saving storage.

[0027] The method may further comprise forming a customized figure by interchanging at least one of (a) an outer body piece coupled to the body piece or (ii) an appendage piece selected from a set associated with a different three-dimensional plush figure.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings illustrate embodiments of the disclosed subject matter. In the drawings:

[0029] FIG. 1 is a perspective view of an example three-dimensional plush puzzle system assembled as an animal FIGURE(rabbit example).

[0030] FIG. 1A is a cross-sectional view as taken through 1A-1A of FIG. 1.

[0031] FIG. 2 is a perspective view of example pieces of the three-dimensional plush puzzle system of FIG. 1 shown in a disassembled state.

[0032] FIG. 3 is a perspective view of a pair of example pieces of the three-dimensional plush puzzle system of FIG. 1, and further illustrating example slot widths and piece thicknesses.

[0033] FIG. 4 is an assembled view for a cat configuration of the three-dimensional plush puzzle system of the present disclosure.

[0034] FIG. 5 illustrates example pattern pieces for the cat configuration of the three-dimensional plush puzzle system of FIG. 4.

[0035] FIG. 6 is an assembled view for an elephant configuration of the three-dimensional plush puzzle system of the present disclosure.

[0036] FIG. 7 illustrates example pattern pieces for the elephant configuration of the three-dimensional plush puzzle system of FIG. 6.

[0037] FIG. 8 illustrates an assembled view for a horse configuration of the three-dimensional plush puzzle system of the present disclosure.

[0038] FIG. 9 illustrates an assembled view for a pig configuration of the three-dimensional plush puzzle system of the present disclosure.

[0039] FIG. 10 illustrates an assembled view for a dog configuration of the three-dimensional plush puzzle system of the present disclosure.DETAILED DESCRIPTION

[0040] The present application relates to puzzles made of plush. More specifically, the present application relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, aliens, robots, vehicles, buildings) wherein each piece of the puzzle is made of plush or other stuffed construction and the pieces are joined to one another in a threaded or dovetail-like or half-lap joint manner.

[0041] As illustrated in FIGS. 1-2, the three-dimensional plush puzzle system is generally designated by reference character 100. When assembled, the three-dimensional plush puzzle system 100 forms a three-dimensional figure such as an animal (e.g., a rabbit, dog, cat, elephant, horse, pig), although any other figure or object is contemplated, including dolls, creatures, aliens, robots, buildings, castles, vehicles, cars, planes, and boats.Puzzle Pieces

[0042] Each three-dimensional plush puzzle system 100 includes a body or core piece 110 and at least one appendage piece 120. The body piece 110 may constitute a torso or central support of the figure, and the appendage piece(s) 120 may constitute arms, legs, ears, tails, trunks, faces, heads, wings, fins, or other features.

[0043] The body piece 110 defines an outer perimeter 110a and one or more body slots 112 projecting or extending into the body piece 110 from the outer perimeter 110a. The body piece 110 has a thickness “T1”, and each body slot 112 has a width “W1”. The body slot(s) 112 may have equal or varying depths extending into the body piece 110 depending on the size and shape of the appendage piece(s) 120 to be received.

[0044] Each appendage piece 120 defines an outer perimeter 120a and one or more appendage slots 122 extending or projecting into the appendage piece 120 from the outer perimeter 120a. Each appendage piece 120 has a thickness “T2”, and each appendage slot 122 has a width “W2”. The appendage slot(s) 122 may have equal or varying depths extending into the appendage piece 120 depending on the intended connection to the body piece 110 or to another appendage piece.

[0045] Although the body piece 110 and appendage piece(s) 120 may be planar, it is also contemplated that one or more pieces may be non-planar or curved to more accurately represent an intended figure or to increase stability in the assembled configuration.

[0046] The slots, namely, body slots 112 and appendage slots 122, may extend along an axis “X” which is orthogonally angled into the respective body piece 110 or appendage piece 120 with respect to a plane or chord “P1” (see FIG. 5) extending perpendicular to the respective outer perimeter 110a, 120a. Alternatively, the slots, namely, body slots 112 and appendage slots 122, may extending along an axis “Y” which is non-orthogonally angled into the respective body piece 110 or appendage piece 120 with respect to a plane or chord “P1” extending perpendicular to the respective outer perimeter 110a, 120a.

[0047] In embodiments, the appendage pieces 120 may be flexible along a portion or substantially along an entire length thereof, and may include an integrated wire 120b (see FIGS. 4-5) to form a tail, and to permit the tail to be curved or shaped as desired.Slot-Based Interlocking Connection

[0048] In accordance with the present disclosure, the width “W1” of the body slot(s) 112 is substantially equal to or larger than the thickness “T2” of the appendage piece(s) 120, and the width “W2” of the appendage slot(s) 122 is substantially equal to or larger than the thickness “T1” of the body piece 110 to which the appendage piece 120 is to be attached. In this manner, a body slot 112 may receive a portion of an appendage piece 120, and an appendage slot 122 may receive a portion of the body piece 110 when the pieces are joined, in the manner of a lap joint or half-lap joint.

[0049] More specifically, the body piece 110 defines a body plane and each appendage piece 120 defines an appendage plane. During connection of an appendage piece 120 to the body piece 110, the appendage piece 120 is oriented such that the appendage plane is transverse (e.g., orthogonal) to the body plane. Once so oriented, a body slot 112 is aligned with an appendage slot 122 and the body piece 110 and appendage piece 120 are fed into or threaded into one another such that a portion of the body piece 110 is received into the appendage slot 122 and a portion of the appendage piece 120 is received into the body slot 112, in the manner of a lap joint or half-lap joint.

[0050] In some embodiments, the body slots 112 and the appendage slots 122 are sized to create a friction fit that retains the pieces in an assembled state during normal play. Additionally or alternatively, the system 100 may include a secondary retention feature, such as a hook-and-loop patch, snap, button, magnet, or tether, positioned adjacent a slot to inhibit unintended separation while still permitting disassembly.Materials and Construction

[0051] One or more of the body piece 110 and appendage pieces 120 may be fabricated from plush, smocking, velour, velvet, felt, artificial fur, flocking, foam, or the like. In an embodiment, the body piece 110 and / or the appendage piece(s) 120 are constructed entirely or at least in part of a compressible and resilient material (e.g., foam). In an example construction, as illustrated in FIG. 1A, a piece (e.g., body piece 110 or appendage piece 120) includes a rigid or semi-rigid core “C” (see FIG. 2) made of a material (e.g., cardboard, pressboard, plastic sheet, or fiberboard) that provides structural support. The core “C” may be covered by a cushioning or outer layer “CL” (e.g., foam) and further covered by an outer textile or plush layer “PL” (e.g., plush, velour, velvet, artificial fur).

[0052] In some examples, as illustrated in FIG. 1A, one or more pieces include a rigid or semi-rigid core “C” (e.g., cardboard or pressboard), optionally a cushioning layer “CL” (e.g., foam), and an outer plush layer “PL” (e.g., plush fabric, velour, velvet, felt, artificial fur).

[0053] The body or appendage piece perimeter 110a, 120a may be finished using stitching, binding tape, heat sealing, adhesive, or other edge finishing techniques. The edges of slots 112, 122 may be reinforced using stitching, binding, lamination, grommets, or localized stiffeners to reduce wear and maintain dimensional tolerances.Kits and Variations

[0054] The system 100 may be provided as a kit including a plurality of pieces that can be assembled into a selected figure. In some embodiments, different sets of appendage pieces 120 can be interchangeably coupled to a common body piece 110 to form different figures(e.g., different animals) or different poses of the same figure.

[0055] In some embodiments, the kit includes multiple sets of appendage pieces configured as different animals or characters. For example, FIGS. 3-8 illustrate non-limiting example configurations (cat, dog, elephant, horse, pig) that share common interlocking principles while using different body profiles and appendage profiles.

[0056] In these examples, a body piece includes multiple body slots positioned around the perimeter at locations corresponding to at least one of front legs, back legs, ears, tail, neck, or a face piece. Appendage pieces (e.g., legs, ears, tail, trunk, face) each include one or more appendage slots that engage a corresponding body slot, or other appendage pieces.

[0057] The example templates of FIGS. 3-8 further illustrate that different appendage categories may be shaped and slotted differently. For instance, a leg piece may define a central appendage slot sized to receive a portion of the body piece, while an ear piece may define a shorter appendage slot positioned near a base region of the ear piece. A face piece may include multiple appendage slots to receive portions of multiple other pieces and / or to couple to a body slot.

[0058] In some embodiments, at least one appendage piece includes an internal bendable member 230 (e.g., a wire) that permits the appendage piece to be posed or curved. For example, FIGS. 3, 7, and 8 illustrate a tail piece that may include a bendable wire to allow a user to curve the tail in different directions while the tail remains coupled to the body piece.Disassembly and Compact Storage

[0059] In use, the assembled three-dimensional plush figure may be disassembled by reversing the threading operation described above, thereby separating the appendage piece(s) from the body piece. Because the pieces may be generally planar and include slots extending inward from the perimeter, the pieces may be stored in an unassembled state substantially flat. In some embodiments, the pieces are stacked, nested, or otherwise arranged in a compact bundle for shipping and / or for space-saving storage in a drawer, backpack, suitcase, or toy bin. This flat or compact storage configuration can reduce packaging size and shipping volume relative to a pre-assembled plush toy.

[0060] Interchangeable Parts and Custom Figures. In some embodiments, one or more pieces are standardized such that components are interchangeable across different figure themes. For example, a body piece may function as a core that couples to one or more outer body pieces (e.g., a removable outer body covering, sleeve, shell, or skin) having different characters, textures, colors, and / or printed indicia, while maintaining compatible slot locations. In some embodiments, an outer body piece is coupled to the body / core piece using one or more slots, hook-and-loop patches, snaps, magnets, or other releasable fasteners.

[0061] Additionally or alternatively, appendage pieces from different three-dimensional plush figures(e.g., from different kits) may share common slot dimensions and / or standardized slot locations and can therefore be coupled to a selected body piece. In this manner, a child may combine ears, tails, limbs, faces, wings, and / or accessories from different sets to create hybrid or imaginative characters. In some embodiments, the kit includes a plurality of appendage pieces having multiple different aesthetic designs but compatible connection geometry, thereby encouraging creative customization while preserving stable interlocking assembly.

Examples

Embodiment Construction

[0040]The present application relates to puzzles made of plush. More specifically, the present application relates to three-dimensional puzzle systems for constructing figures(e.g., dolls, animals, creatures, aliens, robots, vehicles, buildings) wherein each piece of the puzzle is made of plush or other stuffed construction and the pieces are joined to one another in a threaded or dovetail-like or half-lap joint manner.

[0041]As illustrated in FIGS. 1-2, the three-dimensional plush puzzle system is generally designated by reference character 100. When assembled, the three-dimensional plush puzzle system 100 forms a three-dimensional figure such as an animal (e.g., a rabbit, dog, cat, elephant, horse, pig), although any other figure or object is contemplated, including dolls, creatures, aliens, robots, buildings, castles, vehicles, cars, planes, and boats.

Puzzle Pieces

[0042]Each three-dimensional plush puzzle system 100 includes a body or core piece 110 and at least one appendage piec...

Claims

1. A three-dimensional puzzle system comprising:a body piece having an outer perimeter and defining at least one body slot extending inward from the outer perimeter;an appendage piece having an outer perimeter and defining at least one appendage slot extending inward from the outer perimeter;wherein the body piece has a first thickness and the appendage piece has a second thickness;wherein a width of the at least one body slot is at least the second thickness and a width of the at least one appendage slot is at least the first thickness;wherein the body piece and the appendage piece are configured to be assembled by orienting the appendage piece transverse to the body piece, aligning the at least one body slot with the at least one appendage slot, and threading the body piece and the appendage piece into one another such that a portion of the body piece is received within the at least one appendage slot and a portion of the appendage piece is received within the at least one body slot to form a three-dimensional figure; andwherein the body piece and the appendage piece are formed at least in part of a compressible and resilient material.

2. The three-dimensional puzzle system of claim 1, wherein the appendage piece is configured to be oriented substantially orthogonal to the body piece during said threading.

3. The three-dimensional puzzle system of claim 1, further comprising:a plurality of appendage pieces, each appendage piece including a respective appendage slot configured to interlock with a corresponding body slot of the body piece.

4. The three-dimensional puzzle system of claim 3, wherein the body piece defines a plurality of body slots distributed around the outer perimeter of the body piece.

5. The three-dimensional puzzle system of claim 1, wherein at least one of the body slot or the appendage slot has a depth selected to position an exterior surface of the body piece substantially flush with an exterior surface of the appendage piece when assembled.

6. The three-dimensional puzzle system of claim 1, wherein at least one of the body piece or the appendage piece comprises a rigid or semi-rigid core layer and an outer plush layer covering the core layer.

7. The three-dimensional puzzle system of claim 6, wherein the at least one of the body piece or the appendage piece further comprises a cushioning layer disposed between the rigid or semi-rigid core layer and the outer plush layer.

8. The three-dimensional puzzle system of claim 1, wherein the appendage piece comprises an outer textile layer comprising at least one of plush, velour, velvet, felt, artificial fur, or flocking.

9. The three-dimensional puzzle system of claim 1, wherein at least one of the body piece or the appendage piece is non-planar.

10. The three-dimensional puzzle system of claim 1, wherein the body piece and the appendage piece are configured to be retained in an assembled state by a friction fit between surfaces of the slots and surfaces of received portions of the pieces.

11. The three-dimensional puzzle system of claim 1, wherein the body piece and the appendage piece are selectively capable of disassembly by reversing the threading such that the pieces separate into an unassembled state.

12. The three-dimensional puzzle system of claim 11, wherein, in the unassembled state, at least a plurality of the pieces are substantially planar and are configured to be stored substantially flat or stacked to reduce storage volume.

13. The three-dimensional puzzle system of claim 12, wherein the pieces are packaged for shipment in the unassembled state in a compact stacked arrangement.

14. The three-dimensional puzzle system of claim 1, further comprising an outer body piece configured to be removably coupled to the body piece to change an appearance of the three-dimensional figure.

15. The three-dimensional puzzle system of claim 14, wherein the outer body piece is coupled to the body piece using a selectively closable connection.

16. The three-dimensional puzzle system of claim 1, wherein the appendage piece is interchangeably couplable with the body piece and at least one additional appendage piece from a different three-dimensional plush figure kit based on compatible slot dimensions.

17. The three-dimensional puzzle system of claim 1, wherein the appendage piece is flexible along at least a portion of a length thereof, and wherein the appendage piece includes a wire integrated into at least a portion of the length thereof.

18. The three-dimensional puzzle system of claim 1, wherein the body piece and each appendage piece is joined via a half-lap joint between the body piece and each appendage piece.

19. A method of assembling and storing a three-dimensional plush puzzle, the method comprising:assembling a body piece and an appendage piece as recited in claim 1 by orienting the appendage piece transverse to the body piece, aligning a body slot with an appendage slot, and threading the body piece and the appendage piece into one another to form a three-dimensional figure;disassembling the three-dimensional figure by reversing the threading to separate the body piece and the appendage piece; andstoring the separated pieces in a substantially flat or compact stacked arrangement for shipping or space-saving storage.

20. The method of claim 19, further comprising forming a customized figure by interchanging at least one of (a) an outer body piece coupled to the body piece or (ii) an appendage piece selected from a set associated with a different three-dimensional plush figure.

Images