Abstract:
The present disclosure relates to a magnetic module assembly having opposing geometric frames and a plurality of connector struts that connect and extend between the geometric frames. Each of the geometric frames has a plurality of segments, with each segment having a magnet enclosure integrated in the segment. The segments are interposed between attachment points formed in the geometric frame, each attachment point having a pair of receptacles that are sized and shaped to receive a corresponding pair of connector pins from a connector strut. The segments of a geometric frame have a larger thickness compared to that of the attachment points, making the attachment points of the frame frangible.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims the benefit of U.S. Provisional Patent Application No. 62/293,938, filed on Feb. 11, 2016, which is incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The following disclosure relates to magnetic modules, and more particularly, to magnetic modules that may be used with other like modules in a toy construction kit for building structures. 
       BACKGROUND OF THE INVENTION 
       [0003]    Magnetic construction kits have become a popular category for children&#39;s toys. These kits ordinarily include construction modules having magnets embedded therein that enable the modules to be connected together via magnetism. Using these modules, children are able to assemble many imaginative two-dimensional and three-dimensional shapes and structures, thereby imparting great enjoyment and entertainment to the children using them. 
       SUMMARY OF THE INVENTION 
       [0004]    In view of the foregoing background, a magnetic modular block assembly is disclosed. The assembly includes opposing first and second geometric frames and a plurality of connector pieces or struts that interconnect the first and second geometric frames. Each of the geometric frames has a plurality of segments or legs interposed between a corresponding number of corners formed in the geometric frame, with each corner being sized and shaped to (1) interface with one of the plurality of connector pieces or struts, thereby allowing the connector pieces or struts to interconnect the geometric frames; and (2) be frangible such that whenever the frame experiences significant stress through twisting or blunt force, one or more of the corners will break to relieve such stress before the segments or legs do. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    For a more complete 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: 
           [0006]      FIG. 1  is a perspective view of a three-dimensional magnetic module assembly constructed in accordance with an embodiment of the present invention, the assembly having two opposing square-shaped frames and four connector struts which interconnect with the square-shaped pieces; 
           [0007]      FIG. 2  is an exploded view of the assembly shown in  FIG. 1 ; 
           [0008]      FIG. 3  is a top plan view of one of the square-shaped frames depicted in  FIGS. 1 and 2 ; 
           [0009]      FIG. 4  is a top plan view of one of the connector struts depicted in  FIGS. 1 and 2 ; 
           [0010]      FIG. 5  is a perspective view of the square-shaped frame shown in  FIG. 3 , with potential deformations of two sides of the square-shaped frame shown in broken lines; 
           [0011]      FIG. 6  is a perspective view of a three-dimensional magnetic module assembly constructed in accordance with another embodiment of the present invention, the assembly having two opposing triangle-shaped frames and three connector struts which interconnect with the triangle-shaped frames; 
           [0012]      FIG. 7  is a perspective view of a three-dimensional magnetic module assembly constructed in accordance with another embodiment of the present invention, the assembly having two opposing semi-circular (i.e., 90°) frames and three connector struts which interconnect with the semi-circular frames; 
           [0013]      FIG. 8  is a perspective view of a plurality of three-dimensional magnetic module assemblies constructed in accordance with other embodiments of the present invention; 
           [0014]      FIG. 9  is a perspective view of a three dimensional magnetic module assembly constructed in accordance with another embodiment of the present invention, the assembly having four arcuate frames which are interconnected (i.e., in end-to-end fashion) to give the assembly a cylindrical shape; and 
           [0015]      FIG. 10  is a perspective view of a three dimensional magnetic module assembly constructed in accordance with another embodiment of the present invention, the assembly having four triangular frames which are curved and interconnected (i.e., in side-by-side fashion) to give the assembly a hemispherical shape. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    The following disclosure is presented to provide an illustration of the general principles of the present invention and is not meant to limit, in any way, the inventive concepts contained herein. Moreover, the particular features described in this section can be used in combination with the other described features in each of the multitude of possible permutations and combinations contained herein. 
         [0017]    All terms defined herein should be afforded their broadest possible interpretation, including any implied meanings as dictated by a reading of the specification as well as any words that a person having skill in the art and/or a dictionary, treatise, or similar authority would assign thereto. 
         [0018]    Further, it should be noted that, as recited herein, the singular forms “a”, “an”, and “the” include the plural referents unless otherwise stated. Additionally, the terms “comprises” and “comprising” when used herein specify that certain features are present in that embodiment. However, this phrase should not be interpreted to preclude the presence of additional steps, operations, features, components, and/or groups thereof. 
         [0019]    Turning now to the figures,  FIGS. 1 and 2  illustrate a three-dimensional cubic block assembly  10  constructed in accordance with an embodiment of the present invention. The assembly  10  is made from two square-shaped frames  12   a,    12   b  and four connector pieces or struts  14   a,    14   b,    14   c,    14   d  that interconnect and extend between the frames  12   a,    12   b.  Each of the square-shaped frames  12   a,    12   b  has four side segments or legs  16   a,    16   b,    16   c,    16   d,  each of which includes a magnet enclosure  18 , as does each of the connector struts  14   a,    14   b,    14   c,  and  14   d.  Each magnet enclosure  18  is positioned to be facing toward the outside of the assembly  10  and defines a point of contact for the assembly  10  to magnetically connect with other magnetic modules. 
         [0020]    Turning to  FIG. 2 , an exemplary magnet enclosure  18  comprises a cavity  20  at an outer edge  46   a  of the frame  12   a  inside which a bar magnet  22  (see  FIG. 2 ) is located, and a cap  24  to secure the magnet  22  within the cavity  20 . The cavity  22  is sized and shaped to receive the magnet  22  such that the longitudinal axis of the magnet  22  is substantially parallel to the outer edge  46   a  at the location of the cavity  20 . The cap  24  covers magnet  22  and the cavity  20  so as to prevent the magnet  22  from escaping the cavity  20  in instances where the magnet enclosure  18  experiences significant shear or rotational stress (e.g., when shearing or rotational stress to the frame  12   a ). In one embodiment, the cap  22  is secured to the cavity  20  using ultrasonic welding. An exemplary connector strut  14   c  also has a magnet enclosure  18  having a cavity  20 , a bar magnet  22 , and a cap  24  in essentially the same arrangement as is shown and discussed with respect to frame  12   a,  except that the magnet enclosure  18  of the connector strut  14   c  is at an edge  46   c  of the connector strut  14   c,  rather than at edge  34   a  of frame  12   a.    
         [0021]    Continuing to refer to  FIG. 2 , an exemplary embodiment of the frame  12   a  has a groove  910  in the frame  12   a  located adjacent the cavity  20  and substantially parallel to the edge  46   a.  A similarly arranged groove (not shown) is present on the opposite side (not shown) of the frame  12   a.  The cap  24  has a C-shaped cross-section and teeth  912 ,  914  proximate opposite ends  916 ,  918  of the cap  24 . The cap  24 , teeth  912 ,  914 , and groove  910  are arranged such that the cap  24  attaches to the frame  12   a  with the tooth  912  fit into the groove  910  and the tooth  914  fit into the groove on the opposite side of the frame  12   a  in a snap fit. In the exemplary embodiment of the frame  12   a,  nubs  920 ,  922  extend from the cavity  20  and are sized and shaped such that the cap  24  covers the nubs  920 ,  922 , the cavity  20 , and the magnet  22  with the outer surface  924  of the cap  24  flush with the outer surface  926  of the frame  12   a.  The exemplary connector strut  14   c  has an arrangement of its respective groove  910 , teeth  912 ,  914 , nubs  920 ,  922 , and cap  24  that is essentially the same as shown and discussed with respect to frame  12   a,  except that the magnet enclosure  18  of the connector strut  14   c  is at an edge  46   c  of the connector strut  14   c,  rather than at edge  34   a  of frame  12   a,  and the outer surface of connector strut  14   c  is outer surface  928 . 
         [0022]    Continuing to refer to  FIG. 2 , each frame in the assembly  10  (i.e., frames  12   a  and  12   b ) has a plurality of attachment points (i.e., corners  26   a,    26   b,    26   c,  and  26   d ) located at the intersections of the side segments  16   a - 16   d.  Each connector strut in the assembly  10  (i.e., connector struts  14   a - 14   d ) has a first attachment end located at one end of the connector strut (see first attachment ends  28   a,    28   b,    28   c,  and  28   d ) and a second attachment end located at an opposite end of the connector strut (see second attachment ends  30   a,    30   b,    30   c,  and  30   d ). The first attachment ends  28   a - 28   d  and the second attachment ends  30   a - 30   d  of the connector struts  14   a - 14   d  are sized and shaped to interface with the attachment points  26   a - 26   d  located on each of the frames  12   a,    12   b.  The attachment points of the frames and the attachment ends of the connector struts will be discussed in greater detail below. 
         [0023]      FIGS. 3 and 4  provide detailed views of a square-shaped frame  12  and a connector strut  14 , respectively, each constructed in the same manner as the frames  12   a,    12   b  and the connector struts  14   a - 14   d  shown in  FIGS. 1 and 2 . Referring to  FIG. 3 , the side segments  16   a,    16   b,    16   c,    16   d  of the frame  12  each include an inner edge (see inner edges  32   a,    32   b,    32   c,  and  32   d ), an outer edge (see outer edges  34   a,    34   b,    34   c,    34   d ), and a thickness h defined by the distance between a side segment&#39;s outer edge and its corresponding inner edge (e.g., the distance between inner edge  32   a  and outer edge  34   a  of side segment  16   a ). As discussed above, each of the side segments  16   a - 16   d  also houses a respective one of the magnet enclosures  18  proximate to its outer edge (i.e., outer edges  34   a - 34   d ). In one embodiment, each of the inner edges  32   a - 32   d  has a curved shape which provides structural support and a resistance to twisting to each of the side segments  16   a - 16   d.    
         [0024]    Still referring to  FIG. 3 , the attachment points  26   a,    26   b,    26   c,    26   d  of the frame  12  are integrally connected to their respective adjacent side segments (i.e., attachment point  26   a  is integrally connected to side segments  16   a  and  16   d,  attachment point  26   b  is integrally connected to side segments  16   b  and  16   a,  attachment point  26   c  is integrally connected to side segments  16   c  and  16   b,  and attachment point  26   d  is integrally connected to side segments  16   d  and  16   c ). The attachment points  26   a - 26   d  include corresponding apertures  36   a,    36   b,    36   c,    36   d  and notches  38   a,    38   b,    38   c,    38   d  which extend through the frame  12  depth-wise and serve as the interface through which a respective one of the connector struts  14   a,    14   b,    14   c,    14   d  connects to the frame  12 . The apertures  36   a - 36   d  and notches  38   a - 38   d  are sized and shaped to interface with either the first or second attachment ends of the connector struts  14   a,    14   b,    14   c,    14   d  (e.g., first attachment end  28   a  or second attachment end  30   a ) in a manner discussed in further detail below. 
         [0025]    Each of the apertures  36   a - 36   d  in the attachment points  26   a - 26   d  is located proximate to a corresponding one of the notches  38   a - 38   d,  and the apertures  36   a - 36   d  and their corresponding notches  38   a - 38   d  define medians  40   a,    40   b,    40   c,  and  40   d  in the frame  12 . Each of the medians  40   a - 40   d  extends between two adjacent side segments in the frame  12  (i.e., median  40   a  extends between side segments  16   a  and  16   d;  median  40   b  extends between side segments  16   b  and  16   a;  median  40   c  extends between side segments  16   c  and  16   b;  and median  40   d  extends between side segments  16   d  and  16   c ). Each of the medians  40   a - 40   d  has a thickness j (see  FIG. 3 ) defined by the distance between each aperture and its corresponding notch (e.g., the distance between aperture  36   a  and notch  38   a  of attachment point  26   a ). 
         [0026]    The attachment points  26   a - 26   d  also include outer border (i.e., perimeter) strips  42   a,    42   b,    42   c,    42   d  in the frame  12  (i.e., outer border strip  42   a  is defined by aperture  36   a  and the curved intersection of outer edges  34   a  and  34   d;  outer border strip  42   b  is defined by aperture  36   b  and the curved intersection of outer edges  34   b  and  34   a;  outer border strip  42   c  is defined by aperture  36   c  and the curved intersection of outer edges  34   c  and  34   b;  and outer border strip  42   d  is defined by aperture  36   d  and the curved intersection of outer edges  34   d  and  34   c ). Each of the outer border strips  42   a - 42   d  has a thickness k (see  FIG. 3 ). The combined dimensions of j and k is less than the thickness h (see  FIG. 3 ) of any of the side segments  16   a - 16   d.  This makes the medians  40   a - 40   d  and the outer border strips  42   a - 42   d  frangible in comparison to the side segments  16   a - 16   d  for reasons discussed further below. 
         [0027]    In the embodiment shown in  FIG. 3 , each of the apertures  36   a - 36   d  is enclosed laterally by its corresponding median, outer border strip, and adjacent side segments (e.g., aperture  36   a  is enclosed by median  40   a,  outer border strip  42   a,  and side segments  16   a  and  16   d ) and has a cylindrical shape. By contrast, each of the notches  38   a - 38   d  has a square or rectangular shape on one side and an open end facing the inside of the frame  12  to facilitate interfacing with a connector strut  14 , which will be discussed further detail below. Alternatively, in other embodiments, the apertures  36   a - 36   d  can have a polygonal shape, such as that of a hexagon or an octagon, while the notches  38   a - 38   d  can have a rounded, semicircular shape. Further, in yet another embodiment, the notches  38   a - 38   d  can be replaced with apertures that are enclosed in the frame  12  in a fashion similar to how the apertures  36   a - 36   d  are enclosed by the frame  12 . 
         [0028]    Turning now to  FIG. 4 , the connector strut  14  has an inner edge  44 , an outer edge  46 , and a depth m defined by the distance between the inner edge  44  and the outer edge  46  of the connector strut  14 . As discussed above, the connector strut  14  also houses a magnet enclosure  18  proximate to the outer edge  46 . In one embodiment, the inner edge  44  has a curved shape, thereby giving the connector strut  14  a curved shape that provides structural support and a resistance to twisting. 
         [0029]    As discussed above, the connector strut  14  includes a first attachment end  28  located at one end of the connector strut  14 , and a second attachment end  30  located at the opposing end of the connector strut  14 . Each of the first and second attachment ends  28 ,  30  includes an inner post (see inner posts  48  and  50 ) extending from the attachment end (i.e., first and second attachment ends  28  and  30 , respectively) and located proximate to the inner edge  44  of the connector strut  14 , and an outer post (see outer posts  52  and  54 ) extending from the attachment end (i.e., first and second attachment ends  28  and  30 , respectively) and located proximate to the outer edge  46  of the connector strut  14 . Each of the inner posts  48 ,  50  is sized and shaped to interface (i.e., interconnect) with any one of the notches  38   a - 38   d  in the frame  12 , while each of the outer posts  52 ,  54  is sized and shaped to interface (i.e., interconnect) with any one of the apertures  36   a - 36   d  in the frame  12 . In one embodiment, the inner posts  48 ,  50  have a rectangular prism shape and the outer posts  52 ,  54  have a cylindrical shape. In other embodiments, the inner posts  48 ,  50  have a rounded or semicircular shape while the outer posts  52 ,  54  have a polygonal prism shape, such as that of a hexagonal or octagonal prism. 
         [0030]    Referring back to  FIG. 2 , the manner in which the connector struts  14   a - 14   d  are connected to the frames  12   a  and  12   b  will now be discussed. By way of example, connector strut  14   a  is positioned in relation to the attachment point  26   a  of frame  12   a  such that the outer post  52   a  and the inner post  48   a  of the connector strut  14   a  are axially aligned with the aperture  36   a  and the notch  38   a,  respectively, of the attachment point  26   a.  The connector strut  14   a  is then brought to and fitted against the attachment point  26   a  of the frame  12   a  so that the inner post  48   a  of the connector strut  14   a  interfaces with the notch  38   a  of the attachment point  26   a  and the outer post  52   a  of the connector strut  14   a  interfaces with the aperture  36   a  of the attachment point  26   a.  The connector strut  14   a  is then held in place by a friction fit between the outer border strip  42   a  and the outer post  52   a,  between the outer post  52   a  and the median  40   a,  and between the median  40   a  and the inner post  48   a.  This arrangement ensures that the outside edge  46   a  of the connector strut  14   a  is facing outwardly relative to the frame  12   a  and is substantially aligned with the outer surface of the outer border strip  42   a  of the frame  12   a.  This positioning enables the magnet enclosure  18  embedded in the connector strut  14   a  to make contact with other similarly situated magnet enclosures of other module assemblies. 
         [0031]    The connector strut  14   a  can be removed from the attachment point  26   a  of the frame  12   a  by pulling the connector strut  14   a  away from the frame  12   a,  thereby releasing the inner post  48   a  and outer post  52   a  from the notch  38   a  and the aperture  36   a,  respectively. In one embodiment, the open end of the notch  38   a  facilitates such removal by allowing the connector strut  14   a  to tilt or rotate back and forth about the median  40   a  of the attachment point  26   a  as the connector strut  14   a  is being pulled away from the frame  12   a,  thereby steadily releasing frictional contact between the inner post  48   a  and the outer post  52   a  on one side, and the median  40   a  and the outer border strip  42   a  on the other. This also enables the connector strut  14   a  to more easily release from the attachment point  26   a  of the frame  12   a  when experiencing sheering stress. 
         [0032]    Referring to  FIG. 5 , this disclosure will now discuss what happens when a frame  12  constructed in accordance with the embodiments discussed above experiences sheering or rotational stress, such as when a user twists the frame  12 . As discussed above, the medians  40   a - 40   d  and outer border strips  42   a - 42   d  of the attachment points  26   a - 26   d  are frangible in comparison to the side segments  16   a - 16   d  of the frame  12 . Therefore, when the frame  12  is twisted such that two adjacent side segments (e.g., side segments  16   c  and  16   d ) are forced away from each other in a transverse direction, the resulting sheering stress causes the median and the outer border strip of the attachment point between the two side segments in question (e.g., median  40   d  and outer border strip  42   d  of attachment point  26   d ) to break. This break displaces the side segment  16   d  of the frame  12  as shown in phantom.  FIG. 5  also shows a similar break occurring at attachment point  26   b,  wherein the median  40   b  and outer border strip  42   b  break, thereby displacing side segment  16   a  as shown in phantom. By breaking at the frangible medians  40   b,    40   d  and outer border strips  42   b,    42   d,  the frame  12  maintains the integrity of the adjacent side segments (i.e., side segments  16   a  and  16   b  adjacent to median  40   b  and outer border strip  42   b  and side segments  16   c  and  16   d  adjacent to median  40   d  and outer border strip  42   d ) as well as the respective magnet enclosures  18  of each of the side segments  16   a - 16   d,  thereby preventing the magnets  22  housed therein (not shown in  FIG. 5 ) from escaping. 
         [0033]    Many variants of the cubic block assembly  10  can be made without departing from the scope of the present invention. For example,  FIG. 6  illustrates a three-dimensional triangular prism assembly  110  constructed in accordance with another embodiment of the present invention. The triangular assembly  110  is constructed in a manner similar to that of the cubic assembly  10 , with the exception that frames  112   a,    112   b  have a triangular shape instead of a square shape. As a result, the triangular frames  112   a,    112   b  include only three side segments  116   a - 116   c  and three attachment points  126   a - 126   c,  and the assembly  110  uses only three connector struts  114   a - 114   c  to interconnect the triangular frames  112   a  and  112   b.  The side segments  116   a - 116   c  and attachment points  126   a - 126   c  are constructed similarly to their counterparts in the square-shaped frame  12  shown in  FIG. 3 , and the connector struts  114   a - 114   c  are constructed similarly to the connector strut  14  shown in  FIG. 4 . 
         [0034]      FIG. 7  illustrates another three-dimensional prism assembly  210 , this time having a semi-circular shape (i.e., a 90° wedge shape). As with the triangular assembly  110  shown in  FIG. 6 , the wedge assembly  210  is constructed in a manner similar to that of the cubic assembly  10 , with the exception that wedge-shaped frames  212   a,    212   b  have a semi-circular wedge shape instead of a square shape. As a result, the wedge-shaped frames  212   a,    212   b  include only three side segments  216   a - 216   c  and three attachment points  226   a - 226   c,  and the assembly  210  uses only three connector struts  214   a - 214   c  to interconnect the wedge-shaped frames  212   a  and  212   b.  The side segments  216   a,    216   b  which form the straight edges of the wedge-shaped frame  212   a  are constructed similarly to the side segments  16   a - 16   d  of the square-shaped frame  12  shown in  FIG. 3 , but the third side segment  216   c  has an arcuate shape to create the desired wedge shape. As with the triangular prism assembly  110  shown in  FIG. 6 , the connector struts  214   a - 214   c  of the wedge-shaped prism assembly  210  are constructed similarly to the connector strut  14  shown in  FIG. 4 . 
         [0035]    Other embodiments of the present invention include other prism shapes such as those shown in  FIG. 8 . These embodiments include, but are not limited to, a rectangular prism  310 , a trapezoidal prism  410 , a right triangular prism  510 , an isosceles triangular prism  610 , a pentagonal prism (not shown), and a hexagonal prism (not shown). 
         [0036]    Further embodiments include assemblies with frames which are curved to create three-dimensional geometric shapes with arcuate surfaces. For example,  FIG. 9  illustrates a cylindrical assembly  710  constructed from four rectangular frames  712   a,    712   b,    712   c,    712   d  which are curved along their longest sides by ninety degrees, thereby giving each frame an arcuate shape. When assembled, the four frames  712   a - 712   d  form the shape of a cylinder. As another example,  FIG. 10  illustrates a hemispherical assembly  810  constructed from four triangular frames  812   a,    812   b,    812   c,    812   d  which are curved such that when assembled, they form the shape of a hemisphere. All such shapes are included within the scope of the present disclosure. 
         [0037]    All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. 
         [0038]    It will be understood that the embodiments 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. All such variations and modifications are intended to be included within the scope of the invention as described in the appended claims.