Elastomeric Toy Blocks with Stretchable Connectors
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Solution Overview
Problem
Existing toy blocks made from hard plastic pose safety concerns due to sharp edges, potential choking hazards, and breakage, while softer materials like polymer foam lack sufficient tensile and shear strength for small blocks.
Innovation Solution
Toy construction blocks made from thermoplastic elastomer (TPE) that can elastically stretch by at least 10% without damage, featuring flexible male and female connectors and optional internal chambers that can be filled with non-inhibiting fill materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If toy blocks are made from hard plastic, then they can snap together firmly and remain interconnected, but they have hard edges and corners that make them painful to step upon and can injure feet
Solution Approach 1:
The patent changes the material parameter from hard plastic to soft material (such as soft rubber or foam), fundamentally altering the physical properties of the toy blocks. This allows the blocks to remain safe for children while maintaining interconnection capability through complementary geometric shapes rather than rigid snapping mechanisms.
Solution Approach 2:
The patent applies different local qualities to different parts of the block - the outer surface is made soft and rounded for safety, while the connecting surfaces have precise geometric features (such as protrusions and recesses) that enable firm interconnection. This local differentiation resolves the contradiction between softness for safety and firmness for connection.
2Strength
If toy blocks are made from hard plastic, then they interconnect with tight interference fits, but very tight tolerances are required in manufacturing which complicates and expenses the manufacturing process
Solution Approach 1:
The patent changes the connection mechanism from interference fit (which requires tight tolerances) to geometric complementarity with slight clearance. The protrusions and recesses are designed to fit together like puzzle pieces, allowing for easier manufacturing with relaxed tolerance requirements while still achieving strong interconnection.
Solution Approach 2:
Instead of making the connecting surfaces tight and precise with clearance elsewhere, the patent inverts the approach by using slight clearance in the connection surfaces while maintaining precise geometric complementarity. This inversion simplifies manufacturing while preserving connection strength.
3Object-affected harmful factors
If toy blocks are made from soft polymer foam, then they are safe from injury, but they have low tensile strength and shear strength causing male protrusions to break off on small blocks
Solution Approach 1:
The patent uses composite construction where the blocks are made from soft material (such as soft rubber or foam) but incorporate reinforced connecting features. The male protrusions and female recesses are designed with increased material density or structural reinforcement at the connection points, creating a composite structure that combines the safety of soft material with the strength needed for small blocks to maintain connections.
Solution Approach 2:
The patent segments the block structure into distinct zones: the main body remains soft and safe for children, while the connecting protrusions and recesses are designed as separate reinforced elements. This segmentation allows the soft material to provide safety while the reinforced connection elements provide the necessary tensile and shear strength.
4Object-affected harmful factors
If toy blocks are made larger to prevent ingestion, then they are too hard to bite into, but this limits the versatility of the construction set
Solution Approach 1:
The patent changes the material parameter from hard plastic to soft material, allowing blocks to be made in smaller, more versatile sizes while maintaining safety. The soft material prevents choking hazards and makes the blocks safe for biting, enabling a wider range of block sizes and more diverse construction possibilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The TPE-based blocks provide a safer, more durable, and versatile solution for toy construction, allowing for easy interconnection and separation without damage, while minimizing the risk of injury from sharp edges or breakage.
Implementation Method 1
All the toy construction blocks in the set are molded from a thermoplastic elastomer. This enables each of the blocks to elastically stretch in any direction by at least ten percent without damage.
Data Source
AI summary
A set of toy construction blocks that are molded from a thermoplastic elastomer. This enables each of the blocks to elastically stretch in any direction by at least ten percent. Each toy construction block has a main body with a top surface and a bottom surface. One or more male connector protrusions extend from the top surface. One or more female connector receptacles extend into the bottom surface of the main body. At least one internal chamber is molded within the main body. The internal chamber is separate and distinct from the female connector receptacles. The internal chamber does extend into the male connector protrusions. Each internal chamber can be empty or can be filled with a fill material that does not inhibit the pliability of the main body. The fill material can be liquid, gel and lubricated particles and is preferably visible through the molded thermoplastic elastomer.