Abstract:
Three-dimensional assemblies include substantially planar structural components having various two-dimensional generally polygonal shapes. Each such structural component includes a plurality of magnets positioned substantially at the midpoints of the polygonal sides of the structural component for use in connecting multiple instances of such structural components together, e.g., via the use of interconnecting ferromagnetic balls sized and configured for efficient interaction with such magnets. Such structural components can also include one or more slots extending inward from the peripheral edge surface of the component for use in assembling corresponding structural components together in an interlocking fashion, e.g., to form cruciform.

Description:
[0001]     This application claims the benefit of U.S. Provisional Application No. 60/634,942, filed Dec. 10, 2004, which is herein incorporated by reference in its entirety. 
     
    
     BACKGROUND  
       [0002]     1. Field of the Invention  
         [0003]     The present invention is directed generally to puzzles and toys. More particularly, the present invention is directed to structural components having magnetic surfaces and which can be magnetically and/or mechanically coupled to form three-dimensional assemblies.  
         [0004]     2. Background of the Invention  
         [0005]     Individuals often find enjoyment in the challenge of building aesthetic structural designs and/or functional structural models. Frequently, the utility associated with constructing such structures is found in the creative and/or problem solving process required to achieve a desired structural objective. Currently, construction assemblies that exploit magnetic properties to interlink various structural components and thereby form different two and/or three dimensional structures are known and can provide an added dimension of sophistication to the construction process (see, for example, the magnetic construction toy disclosed in Balanchi U.S. Pat. No. 6,626,727, the modular assemblies disclosed in Vicentielli U.S. Pat. No. 6,566,992, and the magnetic puzzle/toy disclosed in Smith U.S. Pat. No. 5,411,262). In addition, German Patent No. DE 202 02 183 U1 to Kretzschmar describes flat triangles, squares and rectangles used in conjunction with ferromagnetic balls to create a limited range of geometric constructions. The flat shapes disclosed in the Kretzschmar German Patent consist of magnets inserted in the corners of a triangular or square piece, or six magnets in a rectangular plate which can be attached to steel balls to create a limited number of three-dimensional shapes. Thus, conventional construction kits are appealing to persons of all ages in that they allow for both aesthetic and geometric creativity.  
         [0006]     The above-noted magnet construction assemblies each contain a certain number of component parts, which can sometimes limit geometries and stable or secure connections. Thus, a need remains for a magnetic construction assembly that provides more flexibility in both aesthetic and geometric design, and, moreover, that provides an additional degree of design/construction sophistication.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     In accordance with the present invention, substantially planar structural components are provided having various two-dimensional generally polygonal shapes, such as squares and triangles. Each such structural component is sized for easy manipulation and includes a plurality of externally-oriented edge-mounted magnets positioned substantially at the midpoints of the polygonal sides of the structural component for use in connecting multiple instances of such structural components together, e.g., via the use of interconnecting ferromagnetic balls sized and configured for efficient interaction with such magnets. Such structural components can also include one or more slots extending inward from the peripheral edge surface of the component for use in assembling corresponding structural components together in an interlocking fashion, e.g., to form cruciform subassemblies, thereby increasing the stability and rigidity of the assembly. The spacing and orientation of the slots and magnets and the shapes of the structural components are coordinated so as to give one the option of keeping the center-to-center spacing of adjacent ferromagnetic balls substantially constant while at the same time drawing on one&#39;s imagination and creativity in building constructions having a broad variety of sizes, shapes, and/or configurations. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     For a better understanding of the present invention, reference is made to the following detailed description of various exemplary embodiments considered in conjunction with the accompanying drawings, in which:  
         [0009]      FIG. 1  is a perspective top view of a structural component constructed in accordance with a first exemplary embodiment of the present invention;  
         [0010]      FIG. 2  is a side elevational view of the structural component of  FIG. 1 ;  
         [0011]      FIG. 3  is an edge elevational view of the structural component of  FIG. 1  taken along view line  3 - 3  shown in  FIG. 2 ;  
         [0012]      FIG. 4  is a sectional view of the structural component of  FIG. 1  taken along the section line  4 - 4  shown in  FIG. 2 ;  
         [0013]      FIG. 5  is a sectional view of the structural component of  FIG. 1  taken along section line  5 - 5  shown in  FIG. 3 ;  
         [0014]      FIG. 6  is a perspective top view of a construction made from multiple instances of the structural component of  FIG. 1  assembled together using spherical connecting elements;  
         [0015]      FIG. 7  is a top plan view of the construction depicted in  FIG. 6 ;  
         [0016]      FIG. 8  is a sectional view of the construction of  FIG. 6  taken along the section line  8 - 8  shown in  FIG. 7 ;  
         [0017]      FIG. 9  is a sectional view of the construction of  FIG. 6  taken along the section line  9 - 9  shown in  FIG. 7 ;  
         [0018]      FIG. 10  is a sectional view of an alternative embodiment of the structural component of  FIG. 1  taken along the equivalent of section line  5 - 5  shown in  FIG. 3 ;  
         [0019]      FIG. 11  is a side elevational view of a structural component constructed in accordance with a second exemplary embodiment of the present invention;  
         [0020]      FIG. 12  is a perspective top view of two instances of the structural component of  FIG. 11  in the process of being assembled together;  
         [0021]      FIG. 13  is a perspective top view of a cruciform subassembly formed as a result of the structural components of  FIG. 12  being assembled together in the manner shown in  FIG. 12 ;  
         [0022]      FIG. 14  is a top plan view of a construction made from multiple instances of the cruciform subassembly of  FIG. 13  assembled together using spherical connecting elements;  
         [0023]      FIG. 15  is a perspective top view of a structural component constructed in accordance with a third exemplary embodiment of the present invention;  
         [0024]      FIG. 16  is an edge elevational view of the structural component of  FIG. 15 ;  
         [0025]      FIGS. 17-18  are perspective top views of additional structural components constructed in accordance with the third exemplary embodiment of the present invention;  
         [0026]      FIG. 19  is a top plan view of a construction made from multiple instances of the structural components of  FIGS. 15-18  assembled together using spherical connecting elements;  
         [0027]      FIGS. 20-22  are top views of additional constructions made from multiple instances of the structural components of  FIGS. 15, 16 ,  17  and/or  18  assembled together using spherical connecting elements; and  
         [0028]      FIG. 23  is a top plan view of yet another construction made from multiple instances of the structural component of  FIGS. 15-16  assembled together using a spherical connecting element. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     Referring to  FIGS. 1-3 , there is shown a structural component  10  constructed in accordance with a first embodiment of the present invention. The structural component  10  includes a body  12 , which is substantially planar in configuration, and is substantially square in general peripheral shape. The body  12  of the structural component  10  includes a first major surface  14 , a second major surface  16  opposite and substantially parallel to the first major surface  14 , and a peripheral edge surface  18  disposed between the first and second major surfaces  14 ,  16 . The peripheral edge surface  18  includes four side edges  20 . An interconnection element  22  is disposed in each such side edge  20 , located substantially at the midpoint along the respective length thereof. Though not clearly evident in all of the perspective views, the exposed surface of the magnet is preferably slightly recessed from its surrounding surface if he magnet is intended to attract a non-planer (e.g., spherical) component of the assembly. In this way the magnetic attraction pulls the non-planar component into engagement with the surrounding surface.  
         [0030]     Referring to  FIGS. 1-5 , each interconnection element  22  consists of a recess  24  formed in the associated side edge  20 , which is otherwise substantially linear in shape. The recess includes a substantially spherical side wall  26  having a function to be explained hereinafter. The centerpoint C of the radius R defining each spherical side wall  26  is substantially coplanar with the body  12  of the structural component  10  and centered above the associated side edge  20 . Although the preferred embodiment includes a spherical side wall  26 , in an alternative embodiment side wall  26  includes a cylindrical side wall.  
         [0031]     Each interconnection element  22  further includes a pocket  28  formed within the body  12 , a peripheral flange  30  formed in the edge surface  18  (i.e., in the spherical side wall  26 ) and defining an opening  32  to the pocket  28 , and a magnet  34  contained within the pocket  28  and having an outward-facing magnetic surface  36  adjacent to and coextensive with the opening  32  to the pocket  28  near the edge surface  18 . The peripheral flange  30  includes a substantially planar inner rim  38  adjacent the magnetic surface  36  for retaining the magnet  34  within the pocket  28 , an outer edge  40  having a shape consistent with the locally spherical shape of the adjacent edge surface  18 , and a beveled surface  42  disposed between the inner rim  38  and the outer edge  40 .  
         [0032]     In operation, multiple instances of the structural component  10  can be assembled together with ferromagnetic balls to form stable constructions. Referring to  FIGS. 6-7 , an exemplary construction  44  is shown including multiple instances of the structural component  10 , as well as numerous ferromagnetic balls  46  magnetically connected to, and disposed between, the magnets  34  (see  FIGS. 4-6 ) of the interconnection elements  22  of the structural components  10 . The diameters D of the ferromagnetic balls  46  are substantially equivalent, each such diameter preferably being held to within a tight mechanical tolerance of a common value. As may be seen with reference to  FIG. 2 , the structural component  10  includes two substantially similar dimensions, such dimensions preferably being held to within a tight mechanical tolerance of a common value, and such value being represented by the designation “B”. The “B” designations represent the substantially similar distances as measured between the outward-facing magnetic surfaces  36  of axially-aligned magnets  34  (see  FIGS. 2, 4  and  5 ) contained in the structural component  10 . It will therefore be apparent that close coordination is achieved between and among the positions, configurations, and orientations of the interconnecting elements associated with such structural components. One salutary effect of this close coordination is that the many ferromagnetic balls  46  contained in the construction  44  are caused to be arranged in a regular array  48  having consistent regular horizontal and vertical spacing, which is not only aesthetically pleasing to the eye, but is also conducive to producing constructions of various scales with consistent precision and stability. This also serves to spark the imagination and creativity of one who uses such structural components to build constructions, since there are very few limits on the shape or configuration of constructions that may be built in accordance with the present invention.  
         [0033]     Referring to  FIGS. 8-9 , and as mentioned above, the ferromagnetic balls  46  connect with and/or interconnect the structural components  10  of the construction  44 . More particularly, a ferromagnetic ball  46  can be placed in magnetic contact with the magnetic surface  36  of the magnet  34  of the interconnection element  22  of the structural component  10 . The size and shape of the recess  24 , and specifically of the spherical side wall  26 , is such that the spherical side wall  26  is placed in surface-to-surface spherical contact with the ferromagnetic ball  46  while the ball  46  is simultaneously in contact with the magnetic surface  36 . Thus the ferromagnetic ball  46  is not only allowed to remain in secure magnetic contact with the structural component  10 , it is also kept in a constant position and orientation with respect to the interconnection element  22  by the “seat” provided by the spherical side wall  26 . In an alternative embodiment, the side wall  26  is a cylindrical side wall that aligns with another cylindrical side wall  26  for supporting ferromagnetic ball  46 . However, the “seat” provided by the spherical side wall  26  is preferred to the cylindrical side wall.  
         [0034]     It should be appreciated that numerous advantages are provided by the structural component  10  and/or by constructions (such as the construction  44 ) containing such structural components in assembly with ferromagnetic balls  46  in accordance with the foregoing description. The consistent spacing between the opposite magnetic surfaces of axially-aligned magnets of such a structural component, designated by “B”, ensures consistent center-to-center distances, designated by “A”, between adjacent ferromagnetic balls  44  in the array (e.g., the array  48  of  FIGS. 6-7 ). In addition, disassembly and reassembly can be accomplished with great speed.  
         [0035]     It should also be noted that the structural component  10  can have numerous modifications and/or variations consistent with the first embodiment of the present invention. For example, the structural component  10  can be modified to describe a general planar shape other than that of a square, or even other than that of a polygon. Also, a generally polygonal shape of the structural component  10  can be altered with one or more curved edge surfaces as desired. For another example, one or more of the interconnecting elements of such a structural component can be positioned on an edge surface other than at the midpoint along the length thereof so as not to coincide with the standard spacing of the array formed by the ferromagnetic balls. The same result can be achieved by providing an edge surface that diverges in shape or angle of extension from a more regular (e.g., straight and perpendicular) arrangement. For still another example, and as shown in  FIG. 10 , an alternative structural component  50 , similar to the structural component  10  except as indicated below, can be used in addition to and/or as a replacement for the structural component  10 . More particularly, the structural component  50  has a body  52  formed from two or more parts  54  (e.g., consisting of translucent and/or colored molded plastic) which are substantially hollow and are assembled together, e.g., via ultrasonic welding to form the body  52 . Two or more of the molded plastic parts  54  contain molded wall sections  56  which can be combined to form pockets  58  to hold magnets (not shown) as part of one or more interconnection elements  60  otherwise similar to the interconnection element  22  of the structural component  10 . The magnets (not shown) can be captured in the pockets  58  during body assembly. For a further example, magnets of different types, sizes and shapes can be used, it being recognized that rare-earth magnets in particular can provide exceptional strength per unit volume, and that a cylindrically-shaped magnet can provide excellent dimensional and orientational uniformity in the assembled structural component. In still another example of a modification, the magnets associated with the above-described interconnection elements can be embedded without retaining flanges in the bodies of the structural components.  
         [0036]     Additional exemplary embodiments of the present invention are illustrated in  FIGS. 11-23 . Elements illustrated in  FIGS. 11-23  which correspond substantially to the elements described above with reference to  FIGS. 1-10  have been designated by corresponding reference numerals increased by one or more increments of one thousand. The embodiments of the present invention shown in  FIGS. 11-23  operate and are constructed in manners consistent with the foregoing description of the first embodiment of the invention, unless it is stated otherwise.  
         [0037]     Referring to  FIG. 11 , there is shown a structural component  1010  constructed in accordance with a second embodiment of the present invention. The structural component  1010  includes three interconnection elements  1022 , each of which is similar to the interconnection element  22 , and an interconnection element  1062 . The interconnection element  1062  is located at the midpoint along the length of the associated side edge  1020 , and includes a recess  1064  and a spherical side wall  1066  similar to the recess  24  and the spherical side wall  26 , respectively, except in that the interconnection element  1062  also includes a slot  1068  formed in the spherical side wall  1066 . The slot  1068  includes side walls  1070  oriented substantially parallel to each other, but perpendicular to the linear portion of the associated side edge  1020 . A substantially planar bottom wall  1072  is oriented perpendicular to the side walls  1070  and parallel to the linear portion of the associated side edge  1020 . Similar to the interconnection element  22 , the interconnection element  1062  includes a pocket  1074  formed within the body  1012 , an opening  1076  to the pocket  1074 , and a magnet  1078  contained within the pocket  1074  and having an outward-facing magnetic surface  1080  adjacent to and coextensive with the opening  1078  to the pocket  1074  near the edge surface  1018 .  
         [0038]     In operation, the structural component  1010  can be assembled together with ferromagnetic balls to form stable constructions, which can include a combination of one or more cruciform subassemblies formed when two of the structural components  1010  are assembled together in an interlocking fashion. For example, and as shown in  FIGS. 12-13 , two instances of the structural component  1010  can be oriented such that their respective slots  1068  face each other, after which the structural components  1010  can be merged to the limit allowed by their respective slot bottom walls  1072 . Each of the slots  1068  terminates (i.e., each of the slot bottom walls  1072  fall) at approximately the midpoint of the height of its respective structural component  1010 , such that when two structural components  1010  are merged as just described, the adjacent side edges  1020  of the two structural components  1010  become substantially coplanar, and the adjacent spherical side walls  1026 ,  1066  become spherically aligned. The dimensional width of each slot  1068  closely tracks the thickness of its respective structural component  1010  so as to produce a frictional fit between the two structural components  1010  when the same are merged as described above. Further, the polarities or magnetic domains of the magnets  1078  associated with the respective slots  1068  can be coordinated (e.g., to ensure the north pole of one such magnet  1078  faces the south pole of the other such magnet  1078 ) so as to produce magnetic attraction between the two structural components  1010 . As shown in  FIGS. 13 and 14 , the above-described merging of a pair of structural components  1010  forms a precisely-configured three-dimensional cruciform subassembly  1082 , multiple instances of which can be incorporated into a larger construction for any number of purposes, including contributing structural stability to the assembly.  
         [0039]     Referring to  FIG. 14 , a construction  1084  is shown including multiple instances of the structural component  1010  arranged in the form of cruciform subassemblies  1082 , as well as numerous ferromagnetic balls  1046  magnetically connected to, and disposed between, the magnets  1034  (see  FIG. 11 ) of the interconnection elements  1022  of the structural components  1010 . As shown in  FIG. 14 , constant center-to-center spacing “A” between ferromagnetic balls  1046  is maintained in the same manner as described above with reference to  FIGS. 6-7 .  
         [0040]     Referring to  FIGS. 15-16 , there is shown a structural component  2010  constructed in accordance with a third embodiment of the present invention. The structural component  2010  includes four interconnection elements  2022 , each of which is similar to the interconnection element  22 , except that each of the side edges  2020  in which the interconnection elements  2022  are formed includes a taper  2086  comprising slanted surfaces  2088  adjacent both major surfaces  2014 ,  2016  of the structural component  2010 . The tapers  2086  and the associated slanted surfaces  2088  reduce the peripheral thicknesses of the side edges  2020  and serve other functions as will be described more fully hereinafter.  
         [0041]     Additional structural components constructed in accordance with the third embodiment of the present invention are shown in  FIGS. 17 and 18 , including a structural component  2090  shown in  FIG. 17  and a structural component  2092  shown in  FIG. 18 .  
         [0042]     As shown in  FIG. 17 , the structural component  2090  is in the general shape of an isosceles triangle. More particularly, the structural component  2090  includes two side edges  2094  substantially similar to the side edges  2020  of the structural component  2010 . Such similarity extends to the presence of interconnection elements  2096  located at the midpoint of each such side edge  2094  that are substantially similar to the interconnection elements  2022 , and to the fact that the otherwise linear shapes of the two side edges  2094  form a right angle with respect to each other. The structural component  2096  further includes a substantially linear diagonal side edge  2098  disposed between ends  2100 ,  2102  of the side edges  2094 . The diagonal side edge  2098  includes a taper  2086  and associated slanted surfaces  2088 . An interconnection element  2104  is disposed on the diagonal side edge  2098 , located substantially at the midpoint along the length thereof. The interconnection element  2104  is similar to the interconnection elements  2096 , but contains no magnet or magnet-holding pocket of its own. Instead, nearby magnets  2034  of two interconnection elements  2096  together provide the magnetic attraction by which the interconnection element  2104  functions.  
         [0043]     As shown in  FIG. 18 , the structural component  2092  is in the general shape of an equilateral triangle. More particularly, the structural component  2092  includes three side edges  2106  which are equivalent in length and therefore form three substantially equivalent angles (i.e., measuring approximately sixty degrees each). With the exception of a slightly shorter length, the side edges  2106  are substantially similar to the side edges  2020  of the structural component  2010 . Such similarity extends to the presence of interconnection elements  2108  which are located at the midpoint of each such side edge  2106  and which are substantially similar to the interconnection elements  2022 .  
         [0044]     In operation, one or more instances of the structural components  2010 ,  2090 ,  2092  can be assembled together with ferromagnetic balls to form stable constructions. For example, such constructions can include constructions  2110 ,  2112 ,  2114 ,  2116 ,  2118  formed with ferromagnetic balls  2046  as shown in  FIGS. 19-23 , respectively.  
         [0045]     As shown in  FIG. 19 , the configuration of the construction  2110  is substantially planar, and multiple instances of the structural components  2010 ,  2090 ,  2092  have been interconnected in a creative fashion resembling a mosaic or tile floor.  FIGS. 20, 21  and  22  show the structural components  2010 ,  2090 ,  2092  combined to form the constructions  2112 ,  2114 ,  2116 , each of which extends in three dimensions. The construction  2118  shown in  FIG. 23  also extends in three dimensions, and more particularly illustrates the facility with which multiple instances of the structural component  2010  can be connected to the same ferromagnetic ball  2046  (e.g., with 60 degree spacing therebetween around the perimeter of the ferromagnetic ball  2046 ). Such facility is due at least in part to the narrow profile of the side edges  2020  of the structural component  2010 , which in turn is produced by the slanted surfaces  2088  of the tapers  2086  thereof. As shown in  FIGS. 19-22 , standard center-to-center spacing (i.e., indicated by “A”) between adjacent ferromagnetic balls can be maintained, or if desired, alternative arrangements, such as a hexagonal arrangement  2120  (see  FIG. 19 ) or a pyramidal arrangement  2122  (see  FIG. 22 ), can be produced.  
         [0046]     It will be understood that the embodiments of the present invention described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. For example, the magnet  1078  of the interconnecting element  1068  may be removed and the frictional fit between the two structural components  1010  relied upon to keep such structural components together as part of the cruciform subassembly  1082 . Additionally, other magnetic domains (i.e., north/south polarity arrangements) than those shown in  FIGS. 2 and 11  may be provided with respect to the magnets  34 ,  1034 ,  1078  of the structural components  10 ,  1010 . All such variations and modifications, including those discussed above, are therefore intended to be included within the scope of the present invention. Further, this application is related to co-pending U.S. patent application Ser. No. ______, entitled Magnetic Toy Construction Modules with Corner-Adjacent Magnets by Kowalski et al., filed ______, which is herein incorporated by reference in its entirety.