Abstract:
A magnetic panel system for the construction of structures is disclosed that includes sets of polygonal connector bodies, constructed of plastic or other suitable material, that have corners, edges, and endpoints of rods that are substantially rounded. Hollow, spherical sockets are defined in the corners of the connector bodies with spherical magnets contained therein. The free rotation around any axis that is provided by spherical magnets within spherical sockets assures alignment of magnet fields and mutual attraction of adjacent bodies in many configurations including face-to-face, edge-to-edge, and corner-to-corner combinations, something unavailable with other magnet shapes. Furthermore, equal spacing of sockets in bodies assures magnets are in consistent proximity to other magnets in adjacent bodies. Because spherical magnets adjust within the socket in any direction to form a connection with the greatest magnetic force, the polygonal connector bodies is robust and can be assembled readily making this suitable for young children.

Description:
FIELD 
       [0001]    The present disclosure relates to magnetic construction toys. 
       BACKGROUND 
       [0002]    Toy stores sell a range of magnetic construction sets. One design is shown by Vincentelli (EP 1349626 B1). Vincentelli shows plastic rods that have cylindrical magnets fixed in each end. Spheres of a ferromagnetic material are provided to be the attachment point between magnetic rods. The Vincentelli disclosure suffers several deficiencies. The resulting structures have low structural strength due to the shifting of angles between adjacent magnetic rods. Furthermore, the construction toy of Vincentelli is inappropriate for younger children because the pieces are too small for younger children and because to build anything of consequence requires a large number of rod and metal spheres that is more complex and time consuming than most young children can manage. 
         [0003]    Bong-Seok Yoon (U.S. Pat. No. 7,160,170) describes polygonal bodies incorporating magnets which are loosely contained in compartments. The loosely held magnets doesn&#39;t promote even alignment of adjacent panels, a necessary condition for accurate construction of structures that will allow building multiple levels without collapsing. 
         [0004]    Hunts (U.S. Pat. No. 7,154,363) discloses a magnetic connector apparatus to connect two or more bodies with diametrically magnetized cylindrical magnets. In Hunts, the cylindrical magnets are housed within a cylindrical container that allows the cylindrical magnets to rotate about its z-axis, but prevents rotation in any other axis. Such an arrangement is suitable for connecting two or more bodies along linear borders, but is ill suited for more complicated arrangements as will be discussed below in further detail. 
       SUMMARY 
       [0005]    A magnetic apparatus is disclosed that has: a first polygonal connector body having sockets defined in at least three corners of the connector body, a second polygonal connector body having spherical sockets defined in at least two corners of the connector body, and magnets disposed in each of the sockets. The magnets are free to rotate within their respective sockets around an x-axis, a y-axis, a z-axis, and any combination of the x, y, and z axes. The first polygonal connector body abuts the second polygonal connector so that a first magnet disposed within the first polygonal body is proximate a second magnet disposed within the second polygonal body. The first and second magnets are free to rotate within their associated sockets to minimize external magnetic field. That is, the attractive force between the first and second magnets are maximized with the constraint of being within their respective sockets. 
         [0006]    In some embodiments, the first polygonal connector body has two flat sections each defining a hemispherical portion of each of the spherical sockets. Each flat section has at least two pins and two receptacles, with two pins of the first polygonal connector body engaging with two receptacles of the second polygonal connector body and two pins of the second polygonal connector body engaging with two receptacles of the first polygonal connector body. 
         [0007]    The magnets are spherical and have a first radius. The spherical sockets have a second radius. The first radius is less than the second radius. 
         [0008]    An outer surface of the polygonal connector body proximate at least one of the corners is curved concentrically with respect to the spherical socket proximate the corner. 
         [0009]    When only one corner of the first polygonal body is coupled to a corner of the second polygonal body, the second polygonal body may freely rotate with respect to the first polygonal body. 
         [0010]    Some embodiments include an opening defined in the center of the first polygonal connector body. 
         [0011]    In some embodiments, particularly those having larger polygonal connector bodies, the first polygonal body has an additional socket defined in an edge of the first polygonal body between two sockets defined in adjacent corners of the first polygonal body. A magnet is provided in the additional socket. 
         [0012]    A distance between two sockets along a first side in the first polygonal body is equal to a distance between two sockets in a first side of the second polygonal body. Magnets within the two sockets of the first and second polygonal bodies attract each other when the first sides of the first and second polygonal bodies are brought proximate to each other regardless of the orientation of the first and second polygonal bodies. 
         [0013]    Also disclosed is a magnetic construction apparatus having at least two magnetic connector bodies adapted to magnetically connect one to another. Each magnetic connector body has a plurality of spherical sockets defined within the corners of the magnetic connector body. A spherical permanent magnet is disposed in each of the sockets with clearance provided between the spherical socket and the spherical permanent magnet. The clearance allows the spherical permanent magnet to freely rotate around an x-axis, a y-axis, a z-axis, and any combination of the x, y, and z axes. 
         [0014]    An outside surface of at least one of the corners of the body is substantially concentrically curved with respect to the socket. 
         [0015]    The sockets have a first radius and at least one of the corners of the connector bodies has a second radius, the second radius is greater than the first radius; and the center of the socket and the center of curvature of the at least one of the corners are substantially coincident. 
         [0016]    Some connector bodies having an opening defined in the center. 
         [0017]    In some embodiments, each of the magnetic connector bodies is comprised of two sections that snap together. 
         [0018]    In some embodiments, the two sections have internal strengthening ribs. 
         [0019]    In some embodiments, the magnetic connector bodies are used to represent chemical atoms with at least one of the following denoting atom type: a letter printed on the bodies, a shape of the bodies, and a surface finish of the bodies. 
         [0020]    Also disclosed is a method to manufacture a magnetic connector apparatus by fabricating two sections of a polygonal connector body with each of the two sections having hemispherical sockets defined in at least three corners of each section, placing spherical magnets into the hemispherical socket portions in a first of the two sections, the spherical magnets are free to rotate within their respective sockets around and x-axis, a y-axis, a z-axis, and any combination of the x, y, and z axes, positioning a second of the two sections over the first section such that the hemispherical socket portions of the two sections are mutually aligned, placing the second of the two sections on the first section, and snapping the first section with the second section. 
         [0021]    Each of the two sections have a plurality of receptacles and pins. When placing the second of the two sections on the first section, a first of the pins of the first section engages with a first of the receptacles of the second section and a first of the receptacles of the first section engages with a first of the pins of the second section. 
         [0022]    In some embodiments, the two sections of the polygonal connector body are fabricated by injection molding. 
         [0023]    In some embodiments, an opening is defined in the center section of the polygonal connector body to thereby reduce the amount of material used in fabricating the polygonal connector body. 
         [0024]    The sections of the polygonal connector body may have a plurality of internal strengthening ribs. 
         [0025]    Spherical magnet present a great advantage over other magnet shapes for several reasons. The spherical magnet, when inside a spherical socket that provides a small amount of clearance, can rotate around any axis. This allows two magnets that are in close proximity to align themselves so that magnetic force is maximized. Some magnet configurations have ability to adjust, such as a cylindrical magnet in which one end is a north pole and the other end is a south pole. With a cylindrical magnet that is diametrically magnetized, the magnet can rotate along one axis only. Such magnets provide do not provide strong attraction. Furthermore, they may limit the configurations that can be built. Finally, by rounding corners of the bodies, the spherical magnets can get very close to a spherical magnet in another connector body. Other magnet shapes don&#39;t allow such close proximity. Also, if two connector bodies are connected corner to corner, one of the bodies can spin with respect to the other, something not possible with other magnet shapes. 
         [0026]    By having the magnets provided at the corners of the connector bodies, a more robust structure can be constructed than with some prior art connector bodies in which the magnets are provided in the center of the sides. 
         [0027]    The magnetic connector bodies provide an educational toy that allows construction of structures for young children without the frustration of some prior art systems. In some embodiments, the bodies have openings in the center which can give a small child a place to grab the connector body to aid in frustration-free handling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]      FIGS. 1-4, 6-8, 12, and 22-26  are illustrations of polygonal connector bodies according to embodiments of the disclosure; 
           [0029]      FIG. 5  is an illustration of a spherical magnet showing degrees of freedom of rotation; 
           [0030]      FIGS. 9-11  are illustrations of proximate spherical magnets and the direction of their magnetic attractive forces; 
           [0031]      FIG. 13-21  are illustrations of alternative arrangements of magnets in polygonal connector bodies used to contrast with the embodiments of the disclosure; 
           [0032]      FIG. 27  is a flowchart; 
           [0033]      FIGS. 28-30  are illustrations of polygonal connector bodies arranged to represent molecules. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated. 
         [0035]      FIG. 1  shows an embodiment of the present disclosure. Spherical magnets  12  are housed with a clearance  14 , within spherical sockets  18  which are within polygonal connector bodies  10 . Corners  20  of the polygonal bodies  10  are curved and have a radius that is slightly larger than the radius of sockets  18  which are in turn slightly larger than the radius of magnets  12 . As polygonal bodies  10  are moved toward each other, spherical magnets  12  in adjacent sockets  18  rotate freely within spherical sockets  18  to align N and S poles of magnets and exert mutual force of attraction to each other. In some embodiments, corners  20  are curved so that there is a small separation distance to provide relatively strong mutual force of attraction between polygonal connector bodies  10  in a corner-to-corner connection  16 . 
         [0036]      FIG. 2  shows an end view a plurality of polygonal connector bodies  10 . Spherical magnets  12  are housed within spherical sockets  14  of polygonal connector bodies  10 . Polygonal connector bodies are substantially rounded corners  22 . A plurality of edge-connected bodies form a ring-like structure with an open interior  24 . In some embodiments, polygonal connector bodies  10  include two sections  11  and  13  that are snapped together. A joint  28  shows the place where sections  11  and  13  abut each other. 
         [0037]    In  FIG. 3 , a bar  30  that has magnets  12  in both ends. A corner of polygonal connector body  10  is placed proximate an end of bar  30 . Bar  30  is also made from two sections as suggested by joint  31 . When a torque is imparted to body  10 , it spins freely with respect to bar  30  that is held fixed by hand  26 . This is facilitated by magnets  12  being freely rotatable in sockets  14  and by the corners at interface  34  being rounded that allow the magnets to get close to each other and to attain a position that maximizes the attractive force. A similar effect would occur if hand  26  was holding a body  10  with a corner of the body abutting a corner of another body. 
         [0038]    A polygonal connector body  40  is shown in  FIG. 4 . It is square, except for rounded corners. Sockets  42  are provided in each corner. A magnet is provided in each socket  42 . The diameter of socket  42  is slightly larger than the diameter of magnet  44  to ensure that magnet  44  can freely rotate in socket  42 . Corners  45  are curved with a radius greater than the radii of socket  42  and magnet  44 . A center of the radius associated with curve  45  is substantially coincident with a center of socket  42 . The position of magnets  44  in  FIG. 4  is arbitrary. They could be in any position. 
         [0039]    In  FIG. 5 , a magnet  44  is shown with x, y, and z axes. When magnet  44  is within socket  42 , it may freely rotate about any of combination of the x, y, and z axes. 
         [0040]    In the successive figures, the position of proximate magnets is explored as bodies are put together to form a larger construction. In  FIG. 6 , edges of two bodies  40  are brought proximate to each other. Magnets  50  and  52  move within sockets  44  so that they bump against the edge of its associated socket due to their mutual attraction. It is shown that the S portion of magnet  50  is proximate the N portion of magnet  52 . This is just an example and it could be the opposite polarity. Distance between sockets is standardized such that distances  46  and  48 , as well as distances between all adjacent sockets in bodies  40 . 
         [0041]    In  FIG. 7 , a third body  40  is added to the first two bodies. Magnets  54 ,  56 , and  58  move to the edge of their respective sockets to cause them to be as close as possible. Furthermore, magnets  54 ,  56 , and  58  rotate within the sockets to arrange themselves to maximize the attraction or to put it another way, to minimize the external magnetic field. In  FIG. 8 , four bodies  40  are abutting each other. Magnets  64  and  66  are arranged horizontally and attract each other. Magnets  60  and  62  are arranged vertically and attract each other. Magnets  70 ,  72 ,  74 , and  76  arrange themselves into a small square. The north and south poles arrange themselves on a diagonal to maximize the force of attraction between them. In  FIGS. 9, 10, and 11 , the vertical magnetic force, the horizontal magnetic force, and the diagonal forces among four magnets  70 ,  72 ,  74 , and  76  are shown. 
         [0042]      FIG. 8  shows four bodies  40 . However, for the purposes of being a construction toy for young children, the ability to build larger, more interesting shapes is desired. Referring now to  FIG. 12 , a house is shown with bodies  80 ,  82 ,  84 ,  86 ,  88 , and  90  visible. All of the visible bodies are square, except for equilateral triangle  88 . Magnets  100 ,  102 ,  104 , and  106  arrange themselves in a 3-dimensional arrangement that minimizes external magnetic field (to maximize the attractive forces between them. Corners of bodies  84 ,  86 ,  88 , and  90  are shown as being pointed rather than curved. In an alternative embodiment, they can be curved similar to bodies  80  and  82 . 
         [0043]    It is not an accident that the inventor of the present disclosure has shown spherical magnets in the construction bodies. An inferior alternative is shown in  FIG. 13 , in which a body  110  has bodies that have cylindrical magnets  120  that are diametrically polarized. It is common to consider a cylindrical magnet in which one end is a north end and the opposite end is south. However, such a magnet that is within a socket has only the ability to adjust itself axially within the clearance of the socket. (Sockets are not shown separately in  FIGS. 13-18 , but can be envisioned to be cylindrical with the diameter and length slightly greater than the diameter and length of the cylindrical magnets to allow clearance.) A diametrically polarized cylindrical magnet can rotate within its socket along an axis, such as the y axis shown in  FIG. 13 . 
         [0044]    In  FIG. 14 , two bodies are brought together and there is no orientation of magnets  122  and  124  that provides a strong attractive force. Magnet  122  presents both north and south poles to magnet  124 , thereby both repelling and attracting magnet  124 . 
         [0045]    In  FIG. 15 , the right hand body  110  of  FIG. 14  is rotate 180 degrees to attain the position in  FIG. 15 . In such a configuration, magnets  122  and  130  can rotate along their access so that the north of  122  is aligned with the south of  130  and the north of  130  is aligned with the south of  122 . Magnets  126  and  132  can also rotate to obtain a strong magnetic pole. Thus, although body  110  can be rotated for favorable attraction between the two bodies  110 . However, as the magnetic connector apparatus is targeted for young children, it is undesirable to require the child to flip the body over to facilitate connection. Such a situation will undoubtedly frustrate a child. 
         [0046]    One skilled in the art might suggest that all four magnets be placed in the body with the axis of the cylindrical magnets parallel. If two square bodies are brought proximate each other with all magnets parallel, the magnets will adjust themselves to cause the two bodies to stay together. However, if one of the panels is rotated 90 degrees with respect to the other, such that the magnets are vertical in one of the panels and horizontal in the other panel, the magnets proximate each other will be in the position of the magnets  122  and  124  in  FIG. 14 . Again, such a situation would frustrate a child when trying to build something and finding that about half the time, two bodies won&#39;t attract each other. 
         [0047]    Things are even worse when the polygonal connector bodies are other than squares. Triangles are shown in  FIG. 16 . If the cylindrical magnets in equilateral triangular bodies  150  are pointing toward the corners, little magnetic force is generated between proximate magnets  152  and  154 . In  FIG. 17 , the cylindrical magnets are placed parallel to one of the sides of bodies  160 . When edges of two triangular bodies  160  are placed next to each other, there is a weak force acting to pull bodies  160  together. By rotating one of the bodies, a more favorable position, as shown in  FIG. 18 , can be accessed. Again, the solution is undesirable as it would frustrate a child in having only some of positions providing the desired force to facilitating fabricating structures. 
         [0048]    In the present disclosure, at least some of the magnets are provided in corners of the polygonal bodies. A polygonal body  180  is shown in  FIG. 19  that has magnets  182  disposed in the middle of each side. Such a configuration in which there are no magnets in the corners is inferior for construction as illustrated in  FIG. 20 . Two bodies  180  are brought together along an edge and only one pair of magnets  186  and  188  are proximate each other. In comparison, two bodies  40  of  FIG. 6  have two magnet pairs attracting each other. Thus, there is twice as much force pulling the two bodies together in the configuration in  FIG. 6  as in  FIG. 19 . 
         [0049]    Another problem with the configuration of bodies  180  is illustrated in  FIG. 21 , an end view of bodies  180  that are stacked one on top of the other. Joint  190  is visible in the end view in  FIG. 21 . Because bodies  180  are only constrained at one point, i.e., by the force between magnets  186  and  188 , the two bodies can readily rotate with respect to each other, such as shown in  FIG. 21 , which does not provide a stable construction base. 
         [0050]    Two polygonal bodies  200  that have magnets disposed in the corners have the force of two pairs of magnets holding them together along one edge, as shown in  FIG. 22 . In  FIG. 23 , an end view of polygonal bodies  200  of  FIG. 22  is shown. Bodies  200  do not rotate with respect to each other because they are constrained at both ends, which provides a stable base for further construction. 
         [0051]    Bodies  200  of  FIG. 22  has a central opening  240 . This can be useful in managing the cost by using less material for each body  200 . Additionally, bodies  200  are lighter weight, which are easier for smaller children to handle. Opening  240  can provide a convenient hand hold for construction purposes. 
         [0052]    A body  210 , shown in  FIG. 24 , has magnets at the corners and along each side. Particularly for bodies that are larger in size, more magnets may be provided along the sides to provide a greater magnetic force. 
         [0053]    In some embodiments, the bodies are fabricated out of two sections that are coupled together. A single section of a polygonal connector body is shown in  FIG. 25 . Sockets  222  are provided at the corners of section  220  of a body. Sockets  222  are hemispheres. Hemispherical socket  222  of section  220  mates with a hemispherical socket in another section to form the spherical socket. 
         [0054]    Ribs  224 ,  226 , and  228  are provided to strengthen section  220 , as illustrated in  FIG. 25 . The desired strength can be provided by making the walls thicker or by using the ribs. To limit the amount of material, it is preferred to put in ribs. To hold two sections together, pins  242  are provided that snap into receptacles  240 . 
         [0055]    In  FIG. 26 , an end view of two sections  300  of a body are shown. Hemispherical sockets  302  are provided at the corners. Spherical magnets  304  are placed in the hemispherical sockets  302  of the lower one of sections  300 . Receptacles  306  and pins  308  are provided in both of sections  300 . A receptacle  306  in the upper of sections  300  is aligned with a pin  308  in the lower of sections  300  and vice versa. When they are aligned, the upper of sections  300  is pushed down onto the lower of sections  300  so that aligned pins  308  engage with receptacles  306 . By judicious choice of the locations of pins  308  and receptacles  306 , sections  300  are identical, so that both of sections  300  are made in a single die. 
         [0056]    A process for fabricating a polygonal connector body is shown in  FIG. 27 . In block  500 , two sections of the body are fabricated. A common way to make such parts is by injection molding. However, this is just one non-limiting example. One of the sections is placed horizontally in block  502 . Magnets are placed into the hemispherical sockets of the first section in block  504 . The second section is positioned over the first section aligning pins, receptacles, and hemispherical sockets in block  50 . The second section is moved downward so that the pins and the receptacles snap together in block  508 . 
         [0057]    Referring now to  FIG. 28 , polygonal connector bodies are provided with letters that refer to chemical elements to introduce young children or even those studying high school chemistry to the concept of chemical bonds in molecules. To introduce the chemical makeup of water, H2O, two polygonal connector bodies  600  has a letter H, for hydrogen, printed on the face. Between bodies  600  is a polygonal connector body  602  with the letter O, for oxygen. Bodies  600  are triangles and body  602  is a hexagon. Besides using the letters for identification, the type of polygon can be an indicator for the element. Oxygen has two free electrons each of which shares with one of the hydrogens, which each has a single free electron. To denote sharing of a single electron pair between O and H, the connection is shown as occurring at a point. In  FIG. 29 , a representation for the molecule methane, CH4, is illustrated. Each of the four free electrons in carbon, C, body  612 , bond with a hydrogen, H, body  610 . The single bond is denoted by the hydrogen  610  attaching at a corner of the carbon atom  612 . Bodies  610  are squares with H&#39;s on them to denote hydrogen; and body  612  is a square with a C on it denoting carbon. In some embodiments, bodies  610  are a first color and body  612  is a second, different color. Colors can be used to identify the various atoms making up the molecule. In some embodiments, texture or surface pattern of the bodies is used to indicate the different atom types. Hydrogen (bodies  610  in  FIG. 29 ) can be smooth and carbon (body  612 ) can have a grid pattern, as one non-limiting example. Referring now to  FIG. 30 , an ethane molecule, C2H4, is illustrated. The two carbons  622  share a double bond which leaves two other electrons to be shared with two hydrogens  620  in single bonds. The double bond between the two carbons is shown as an edge-to-edge connection. The single bond between the carbons and their respective hydrogen atoms is illustrated by a point-to-point connection. 
         [0058]    It is common for white boards in classrooms to be ferromagnetic so that magnetized elements can adhere to the white board. The polygonal connector bodies in  FIGS. 28-30  can be placed on such a white board to maintain their respective positions. 
         [0059]    While the best mode has been described in detail with respect to particular embodiments, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are characterized as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.