Post Connector System for Stable Rotating Construction Structures

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Solution Overview

Problem

Existing construction toys lack stability, durability, and ease of assembly, particularly in creating 2D and 3D structures with multiple connected parts that can rotate freely and maintain structural integrity, while also being cost-effective and safe for children.

Innovation Solution

A post connector system comprising a cylindrical rod with attached disks that allow for 360-degree rotation and connection of various geometric shapes, enabling flexible and stable assembly of structures without the need for strong magnets, with optional faceplates for added strength and creativity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If magnetic means are used to join parts, then parts can be connected together, but the structure becomes weak and cannot support downward force or side loading

Engineering Contradiction:

Improvestructural strengthVSAvoiddurability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces magnetic connection with a mechanical hinge system consisting of a hinge pin inserted through aligned holes in component parts. This mechanical connection provides superior strength and durability compared to magnetic forces, enabling the structure to support downward force and side loading while maintaining stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hinge mechanism is segmented into distinct components: hinge pins, hinge holes, and connection elements. This segmentation allows for precise alignment and robust mechanical joining of parts, creating a reliable connection that can withstand various loads without collapse or deformation.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If magnets are used to hold parts together, then parts can be assembled, but the toy becomes expensive and heavy

Engineering Contradiction:

Improvemanufacturing costVSAvoidtoy weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent employs inexpensive mechanical connection elements (hinge pins, plastic or metal connectors) instead of expensive rare earth magnets. These simple mechanical parts are cost-effective to manufacture and can be produced in large quantities without the high material costs associated with strong magnets.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention substitutes magnetic holding forces with a mechanical hinge system that uses simple pins and connectors. This replacement eliminates the need for expensive magnetic materials while providing sufficient holding force for construction toys, thereby reducing both cost and weight.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If strong magnets are used to support larger structures, then larger versions can be built, but they become expensive and potentially dangerous

Engineering Contradiction:

Improvescale capabilityVSAvoidsafety hazards

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The hinge system allows for modular assembly where multiple hinge connections can be distributed throughout a structure. This segmentation enables large-scale constructions to be built using many standard hinge components rather than requiring a single large magnet, thereby maintaining safety while achieving desired size.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces magnetic scaling with mechanical scaling through the hinge system. Larger structures are achieved by adding more hinge connections and component parts rather than increasing magnet strength, eliminating the safety hazards associated with powerful magnets in large-scale toys.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If mechanical connections are used instead of magnets, then parts can be connected strongly, but the hinge is restricted to allowing only two component parts to connect together

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The hinge system is designed with universal applicability through standardized hinge pins and hinge holes that can connect any number of component parts. The same hinge mechanism can join two parts or multiple parts together, providing both strong connection and flexible adaptability for various structural configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges multiple connection functions into a single hinge system. The same hinge pin and hole configuration can serve to connect multiple component parts together, eliminating the need for different connection mechanisms for different numbers of parts and thereby achieving both strength and versatility.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11247142B2Versatile robust construction toy

Publication Date: 2022.02.15 CREATIVE TOYS LLC

AI summary

A cost effective, structural building set, suitable as a toy, uses post connectors (10) comprised of a post (12) with attached disks (14), or similar devices that insert into cutouts (31) in geometric shaped component parts (30, 80, 180). More than one component part can be connected to the same post connector, and such component parts can rotate relative to the post axis. The connector design allows construction of stable structures of many sizes, shapes, and types, and readily facilitates hinging between different sections of such assembled structures.