Abstract:
A modular semi-rigid body construction toy containing a plurality of articulation and accessory attachments to a base body made solely out of a flexible semi-rigid foam material. The toy&#39;s base body and accessories contain internally molded geometry to achieve movement and articulation between the accessory pieces and the toy&#39;s main body. The model also contains connecting links made out of the same flexible foam connect multiple flexible base bodies to create larger articulated flexible toy systems. The modular semi-rigid body construction is built with accurate aesthetic appearances representative of real-world structures, models, and machines.

Description:
BACKGROUND 
       [0001]    1. Field of Invention 
         [0002]    This invention relates to a modular toy that can be assembled and articulated without the use of rigid fastening components or hardware. 
         [0003]    2. Description of Prior Art 
         [0004]    The prior art shows a multitude of building toys. Prior art such as U.S. Pat. No. 8,961,257 and U.S. Pat. No. 9,056,62060 show construction-like toys with semi-rigid and rigid materials such as wire and plastic resin in order to accomplish movement and resiliency. In addition, those items use these rigid pieces as connecting links to give form and function to the models. The same is true for commercial toys that make use of semi-rigid materials and rigid materials to provide for both forma and function. 
         [0005]    The present invention calls for a difference in form and function of the previous prior art construction toys and building systems. Although the prior art achieves a construction toy with flexible form and function, these toys use a plurality of different materials to build construction toys, there still exists a need for a construction toy that can be built without the use of any rigid materials. One particular drawback of the prior art is that their articulating and structural components are made out of rigid materials which mate to the semi-rigid subcomponents. Therefore, there exists the need for a semi-rigid construction toy designed so that the subcomponents can connect and provide articulation and movement without rigid materials. A novel design in the geometry of the flexible toy components is needed to achieve the same articulation and structural resiliency as the rigid components of the existing prior art. The prior art also shows no intent to create models with the intentional accurate aesthetic appearance of real world machines, vehicles, an structures scaled down in a modular form. Therefore, there also exists the need to create a semi-rigid modular construction system that captures the aesthetics accurately representative of real world structures, machines, an vehicles. It is the intention and motivation of the present invention to provide an improvement with the aforementioned needs discussed in the preceding paragraphs in terms of form and function to the existing prior art of flexible construction building toy systems. 
       SUMMARY OF INVENTION 
       [0006]    The present invention relates to a flexible modular toy construction system having a plurality of flexible foam accessories which can be attached to a base flexible form. The accessories of the present invention are attached to the base flexible foam body and together with the base foam flexible body, create an assembled model with moveable parts. In the embodiment of the present invention, multiple connection configurations are possible to achieve realistic articulation representative of an actual real world vehicle, structure, or machine. Examples of the articulation exist in one configuration a flexible foam wheel accessory is designed with internal geometry that connects to a flexible boss of a flexible base body in such a way that the wheel accessory creates a revolute joint with the base flexible body. In another body configuration, a solid flexible foam shaft inserts into a hollow foam cylinder to create a slider joint. Flexible accessories can also be inserted statically into the base body via pureblooded slots in the base body. While some configurations in the present invention provide articulation and movement some flexible accessories connect to the flexible base body for purely an aesthetic purpose. In either case the builder has the option of removing or replacing these components with other accessories of their choosing. 
         [0007]    The advantages of the present invention provide the user with a model building toy that is built with only the flexible components of the model. In addition, the present invention contains only a soft semi-rigid component which make disassembly and reassembly easy. Further still, due to the soft nature of these models, the user does not have to worry about excessive force to remove components or worry about fatigue and failure in the parts as would be with a rigid model. In relation to manufacturing, this toy can be made easily with a one or two-piece mold with an expandable foam not requiring the complexities of injection molding with liquid plastic resin. Further explanation of the configurations and features of the present invention will be explained in the detailing of the drawings. 
     
    
     
       DRAWING DESCRIPTION 
         [0008]      FIG. 1 . Shows the base body of the modular kit with accessory attachment points 
           [0009]      FIG. 2 . Shows the base body in a deformed state 
           [0010]      FIG. 3 . Shows the base body attachment point and accessory in a deformed state 
           [0011]      FIG. 4 . Show the base body wheel attachment mating geometry in a deformed state 
           [0012]      FIG. 5 . Shows a section view of a wheel accessory with mating geometry 
           [0013]      FIG. 6 . Shows a mating slot of the accessory of the base body 
           [0014]      FIG. 7 . Shows a top view of the base body with a engine accessory inserted into a body slot. 
           [0015]      FIG. 8 . Shows an isometric view of the base body with a hood accessory mating over the engine accessory compartment 
           [0016]      FIG. 9 . Shows an exploded view of the base modular kit with accessories 
           [0017]      FIG. 10 . Shows the base body of a modular kit with a different base body geometry 
           [0018]      FIG. 11 . Shows the altered base body in a deformed state 
           [0019]      FIG. 12 . Shows the altered base body&#39;s attachment point in a deformed state 
           [0020]      FIG. 13 . Shows an altered base body wheel attachment geometry in a deformed state accessory 
           [0021]      FIG. 14 . Shows a section view of a wheel accessory of the altered body 
           [0022]      FIG. 15 . Shows a section view of the altered body&#39;s slider sub-component 
           [0023]      FIG. 16 . Shows an exploded view of the alternate base body with the two sub-bodies and a flexible connecting link 
           [0024]      FIG. 17 . Shows an isometric view of the alternate base body with a flexible body link and connecting geometry of the alternate body&#39;s driver component 
           [0025]      FIG. 18 . Shows an isometric view of the alternate base body with a flexible body link and connecting geometry of the alternate body&#39;s chassis component 
           [0026]      FIG. 19 . Shows an isometric view of the alternate body&#39;s chassis component with body link levers 
           [0027]      FIG. 20 . Shows the altered based body in an exploded view 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    The invention presented is a modular toy kit made out of a flexible material. Accessory pieces mate with the base body to create a functional toy. The novelty in this invention is that the attachment points on the base body, as well as the accessory pieces, are made out of the same material which is a soft, semi-rigid, flexible material, such as but no limited to semi-rigid foam. The semi-rigid material is rigid enough to maintain it&#39;s extruded shape, but soft enough to allow deformation so that the accessories can mate together via an interference fits. The joints are similar to joints used on rigid commercial toys, however, the design of the joints of this invention are designed in such that it allows for relative motion between the base body and the accessory without the need for extra connecting hardware such as screws etc. With a little force, the pieces can be pulled apart and re-connected to other base bodies and subcomponents. 
         [0029]      FIG. 1 . Illustrates a base body  10  made in the form of a race car body. The base body is made out of a polyurethane foam. It contains connection points and a hidden compartment for which accessories will be inserted into  11 . 
         [0030]      FIG. 2 . Illustrates the deformed state of the base body  10 . This figure shows the result of the base body after a force is applied in an upward direction on either side of the base body. Due to the flexible foam material, the base body deforms and returns to it&#39;s original shape as shown in  FIG. 1 . 
         [0031]      FIG. 3 . Illustrates the deformed state of the base body attachment boss of the base body  10 , and the wheel accessory  11 . As is shown, the attachment boss of the base body  10 , is flexed and mates with the wheel accessory which is also flexed. 
         [0032]      FIG. 4 . Illustrates the deformed state of the base body&#39;s wheel attachment boss  10 . The outer circumference of the mating geometry deforms to fit into the slotted wheel hub  11 , due to the flexibility of the foam material. 
         [0033]      FIG. 5 . Illustrates the geometry of the wheel accessory  11  that mates to the base body of the modular kit. This view shows the inner connection of the wheel accessory hub  11  which connects to the attachment boss of the base body  10 . The inner connecting hub of the wheel assembly  11  contains a groove whose diameter is slightly larger than the outer diameter of the base body&#39;s attachment boss. When the base body&#39;s attachment boss  10 , is pushed down the barrel of the connecting hub  11 , the outer diameter of the base body slides into the groove and remains positioned in the groove as the outer diameter of the base body&#39;s attachment is slightly larger than the barrel of the wheel accessory  11 . As the attachment boss of the base body  10  is pushed down the barrel of the connecting hub of the wheel accessory  10 , it undergoes compression while the inner hub expands slightly. The attachment boss of the base body  10 , and the hub of the wheel accessory  11 , both return to there original shape once the outer diameter of the attachment boss reaches the inner groove of the inner connecting hub of the wheel accessory  11 . 
         [0034]      FIG. 6 . Illustrates a mating slot in the base body  10  for the purpose of attaching the flexible accessory  12 . The mating slot is designed to maintain a tight fit with the base body when the accessory is inserted. Both the base body  10  and the accessory  12  are designed such that little force is required to disassemble the model  10 . 
         [0035]      FIG. 7 . Illustrates the insertion of an engine accessory  13 , inserted in a planar fashion into a pre-cut slot in the flexible base body  10 . The engine accessory rests in the base body&#39;s slot with the accessory&#39;s  13  geometry pushing against the walls of the slot of the base body  10 . 
         [0036]      FIG. 8 . Illustrates the placement of a hood accessory  14  which mates with the base body. The hood accessory  14  attaches to the main body via a tabbed slot in the base body  FIG. 1 . The geometry of the hood accessory&#39;s tab is slightly larger than the slot on the base body  10  so that the tab pushes again the walls of the slot on the base body. Once inserted, the hood accessory remains flush with base body  10 . 
         [0037]      FIG. 9 . Illustrates different flexible accessory attachments  11 - 14  to the modular kit&#39;s base body. As is shown, the base body  10 , is built up like a model kit but does not require any rigid hardware such as screws in order for the accessory pieces  11 - 14  to remain fixed to the base body  10 . This is possible by the flexible properties of the foam material which the accessories  11 - 14  and base body  10  are made out of. 
         [0038]      FIG. 10 . Illustrates an alternate base body model made out of the same flexible material as the base body in  FIG. 1 . This model contains similar connection points for it&#39;s wheel accessories as shown in  FIG. 1 . 
         [0039]      FIG. 11 . Illustrates the deformed state of the alternate base body configuration. Similar to  FIG. 1 , the model is able to deform due to its flexible material. Once deformed, it can return to its original shape as shown in  FIG. 10 . 
         [0040]      FIG. 12 . Illustrates the deformed state of the attachment boss of the alternate base body  20 . The attachment boss of the alternate base body  20  contains a shaft and a tip boss geometry which will fit into a groove of a wheel accessory  21 . The diameter of the tip boss of the alternate base body  20 , is slightly smaller than the groove to the connecting wheel accessory  21 , creating a revolute joint to allow the wheel accessory  21  to rotate. 
         [0041]      FIG. 13 . Illustrates the deformed state of the alternate body&#39;s wheel attachment boss  20  and mating wheel accessory  21 . The outer circumference of the mating geometry deforms as it is pressed into the mating wheel accessory  21 . 
         [0042]      FIG. 14 . Illustrates the section view of the alternate body&#39;s wheel accessory  21 . Similar to  FIG. 5 , the wheel accessory  21  contains a groove for the alternate body&#39;s attachment tip boss to insert. However, in this configuration, there is no inner hub barrel. Instead, the tip boss is slightly filleted to easily press into the groove of the wheel accessory  21 . Because the tip boss of the alternate body  20  is slightly smaller than the groove of the wheel accessory  21 , but bigger than the channel slot of the wheel accessory  21 , the wheel accessory  21  is able to rotate freely relative to alternate base body  20 . A pulling force must be applied to disengage the wheel accessory  21  from the alternate base body as the diameter of the tip boss of the alternate body  20  is bigger than the channel slot of the wheel accessory  21 . 
         [0043]      FIG. 15 . Illustrates a section view of a subcomponent of the alternate base body shown in  FIG. 10 . This figure shows a sliding mechanism built of two pieces, the extension shaft  24 , and shaft cylinder  23 . As is shown, the extension shaft  24  slides linearly relative to the shaft cylinder  23 , to allow for articulation. A flexible pin  22 , made of the same flexible semi-rigid foam material as the alternate base body  20 , allows the shafts to rotate and remain in place. The pins and shafts have no mechanism to hold them in place other than the force due to friction. This is to easily allow the user to assemble and disassemble the model shown in  FIG. 12 . 
         [0044]      FIG. 16 . Illustrates a alternate base body with a planar connecting link  25  in between a driver  20  and chassis component  26 . The connecting link  25  contains a closed and open hole that connects the two main body components of the alternate body  FIG. 10 . The link also provides articulation between the two sub components. 
         [0045]      FIG. 17  illustrates an alternate body subcomponent  20  and a connector link  25 . A connecting boss is located in a slot on the subcomponent of the alternate body. The closed end of the link connector  25  slides over this boss of the alternate body subcomponent  20 , indicated by the arrow, and creates a revolute joint between the boss and the connector link  25 . 
         [0046]      FIG. 18  illustrates a flexible connector link  25  with the chassis component  26  of the alternate body. A slot in the chassis subcomponent  26  of the alternate body contains a connecting boss. 
         [0047]    This connecting boss is extruded the entire height of the slot. The open end of the connector  25  link mates with the connecting boss in the driver subcomponent  20  by pressing the open end onto the boss of the chassis subcomponent  26 . The open end of the connector link  25  expands due to its foam material properties and rebounds to its original shape forming a crescent shape around the connecting boss of the chassis component  26 . The open end of the connector  25  has a diameter just bigger than the diameter of the connecting boss of the chassis component  26 . The width of the tip of the opening of the connector link  25  is smaller than the with of the connecting boss, thereby keeping the connector link attached to chassis subcomponent. A pulling force is applied to the connector link  25  to disengage the connecting boss of the chassis component  26  of the alternate base body from the connector link  25 . The flexible properties of the connector link  25  allow the open end to expand around the connecting boss of the chassis component  26  when a pulling force is applied at the closed end of the connector link  25 . 
         [0048]      FIG. 19  Illustrates a chassis component  26  and lever arm  27  components of the alternate base body  20 . The two lever arms  27  are connected to the chassis component  26  via shaft pins  22 . The shaft pins  22  are made out of the same flexible foam material as the base alternate body  20  with geometry smaller than the diameter of the hole of the lever arm. The connector shaft pins  22  provide a revolute joint between the lever arms and the chassis subcomponent  26  of the alternate base body  20 . The revolute joint allows the lever arms  27  to move in plane relative to the chassis subcomponent  26 . Other connecting holes are extruded onto the lever arms  27  to allow other sub-components shown in  FIG. 20  to mate to them and provide articulation. 
         [0049]      FIG. 20 . Illustrates the exploded view of the alternate body&#39;s accessories  21 - 28 . As is shown a plurality of components connect to the base body of the alternate base body model  20  to add extra functionality to the body without the use of extra connecting hardware.