Expansion Connector for Toy Building Blocks
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Solution Overview
Problem
Existing toy and model building systems face a challenge in providing a balance between ease of use for children and structural integrity, as systems with friction fits lack strength while those with screws or bolts are difficult for children to use.
Innovation Solution
A building system featuring connectors with flexible sections and alignment posts that expand to lock parts in place, allowing for quick assembly and disassembly without tools, and thumbscrew connectors for added security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If friction fit connectors are used, then ease of operation is improved, but strength deteriorates
Solution Approach 1:
The connector uses a dynamic expansion mechanism where the expansion element transitions from a compressed state during insertion to an expanded state during locking. The flexible sections of the expansion element dynamically adjust their shape to engage with the aperture walls, providing strong structural connection while maintaining ease of operation through simple insert-and-lock motion
Solution Approach 2:
The connector changes the physical state of the expansion element from compressed to expanded form. When the pin is inserted, it forces the flexible sections outward, changing the diameter and shape parameters of the expansion element to create a secure locking engagement with the aperture, thereby transforming the connection strength parameter from weak to strong
2Strength
If screw or bolt fasteners are used, then strength is improved, but ease of operation deteriorates
Solution Approach 1:
The invention extracts the complex threading mechanism of screws and bolts and replaces it with a simplified pin insertion action. The expansion element provides the locking function without requiring rotational motion or threading, thereby maintaining strength while dramatically improving ease of operation for children
Solution Approach 2:
The expansion element performs the locking function automatically through its own elastic deformation when the pin is inserted. The flexible sections self-expand to engage the aperture walls without requiring additional fastening actions, making the connector as easy to use as friction-fit blocks while providing superior structural integrity
3Ease of operation
If expansion mechanism is added, then device complexity is improved, but ease of manufacture deteriorates
Solution Approach 1:
The expansion element utilizes flexible sections that can be manufactured as thin-walled elastic structures. These flexible shells are designed to expand radially when force is applied by the pin, providing the locking mechanism while remaining simple to manufacture through standard elastic material forming processes
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
Enables children to easily build and disassemble structures with strong and resilient connections, combining ease of use with structural integrity.
Implementation Method 1
The expansion element includes a plurality of flexible sections in circumscribing relationship to an aperture in the base. Each of the flexible sections includes an outer lip extending outwardly from a portion of the section distal the base and an inwardly-extending inner lip. A pin is configured to be inserted through the receptacle and into engagement with the expansion element wherein the pin engages the inner lips of the expansion element and forces the flexible sections outward.
Data Source
AI summary
A building system includes connectors for quickly and easily interconnecting building system parts. An expansion connector engages the apertures of two parts and expands to connect the parts. The expansion connector includes a base, an expansion element extending from a first side of the base and a receptacle extending from a second side of the base. A pin is configured to be inserted through the receptacle and the base and into engagement with the expansion element to force the expansion element into an expanded position. An alignment post may extend from the first side of the base to orient the connector relative to the parts and strengthen the connection. A thumbscrew connector includes at least one flange to engage an aperture of at least one part and includes a threaded receptacle for receiving a thumbscrew which secures the connector to the part or parts.