Plastic Magnet Tile Construction for Stable 3D Structures
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Solution Overview
Problem
Existing construction toys face challenges in assembly flexibility, safety concerns due to strong magnetic fields, and cost issues, particularly with rare earth magnets, and insufficient magnetic forces for building three-dimensional structures using plastic magnets which have limited magnetic flux density and are brittle.
Innovation Solution
A planar construction toy system utilizing plastic magnets affixed along the edges of a core with a flexible film and adhesive, providing consistent magnetic attraction forces across a range of angles and allowing for the creation of three-dimensional structures with predictable attachment characteristics, using flexible or rigid films capable of attachment to planar substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If rare earth magnets are used to provide strong magnetic attraction, then magnetic force is improved, but safety concerns increase due to ingestion hazards
Solution Approach 1:
The patent replaces expensive and hazardous rare earth magnets with cheaper, safer plastic magnets that have sufficient magnetic strength for toy construction. The plastic magnets are designed to be non-ingestible or less hazardous, addressing safety concerns while maintaining functionality.
Solution Approach 2:
The patent uses composite plastic magnets that combine magnetic particles with a plastic matrix. This composite structure provides adequate magnetic attraction force while the plastic outer layer reduces safety hazards associated with ingestion of pure rare earth magnets.
2Object-affected harmful factors
If plastic magnets are used to reduce costs and improve safety, then safety and cost are improved, but magnetic flux density decreases making attachment difficult
Solution Approach 1:
The patent combines multiple plastic magnets along the edges of building tiles to create cumulative magnetic attraction force. By merging several weaker magnets into an array, the system achieves sufficient total magnetic force for stable attachment while maintaining the safety and cost advantages of plastic materials.
Solution Approach 2:
The patent transitions from using single strong magnets to using multiple weaker magnets arranged in linear arrays along edges. This dimensional arrangement allows weaker plastic magnets to collectively provide sufficient attachment force through distributed magnetic fields along the edge interfaces.
3Ease of manufacture
If surface polarized plastic magnet tape is used, then manufacturing is simplified, but magnetic force reaches only in direct planar contact direction
Solution Approach 1:
The patent segments the magnetic function into multiple discrete magnets arranged along edges rather than using continuous surface polarized tape. This segmentation allows magnetic fields to extend beyond direct contact points, enabling attachment at relative angles between tile edges while maintaining manufacturing simplicity.
4Strength
If mechanical interlocking structures are used to connect construction elements, then connection strength is improved, but assembly flexibility and ease of operation decrease due to alignment requirements
Solution Approach 1:
The patent replaces mechanical interlocking structures with magnetic attraction forces for connecting construction elements. This substitution eliminates the need for precise alignment and complex interlocking mechanisms, significantly improving assembly ease while maintaining sufficient connection strength through cumulative magnetic forces.
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 system enables the construction of stable three-dimensional structures with improved safety and reduced costs, as it maintains consistent magnetic attraction forces across various angles and orientations, using weaker plastic magnets that are less hazardous and more cost-effective than traditional strong magnets.
Implementation Method 1
plastic magnets affixed along the edges of a core with a flexible film and adhesive, providing consistent magnetic attraction forces across a range of angles
Implementation Method 2
plastic magnets affixed along the edges of a core with a flexible film and adhesive
Data Source
AI summary
A magnetic tile construction set is disclosed that may be used to construct extended 3-dimensional structures. In one embodiment, plastic magnets are attached to multiple edges of a lightweight core. The magnets have a width and length comparable to the thickness of the core and a length that is an order of magnitude longer than the thickness of the core. Tiles may be attached to one another at the tile edges through magnetic forces that do not vary by more than a factor of two over the range of angles from 45 degrees to 180 degrees.