Furniture and large-scale play structures having ideal modularity

A method for building large-scale play structures having an ideal modularity is provided. The method includes providing panels having a thickness, a planar-quadrangle shape including a length, a width and four chamfered edges with a set of holes located along each edge, the holes located at a fixed interval relative to one another, the fixed interval providing a unit of length, a fixed-location fastening element located in each of the holes, respectively; providing a plurality of movable fastening elements each including a hand-grip to allow the respective movable fastening element to be moved between an unsecured position and a secured position without the use of tools when received by any one of the plurality of fixed-location fastening elements; and employing the fasteners to secure a plurality of the panels to one another to provide a structure that has an overall height, an overall length and an overall width, the structure including at least a pair of panels oriented one above the other and at least a pair of panels located at the same elevation and secured at right angles to one another.

BACKGROUND OF INVENTION

1. Field of Invention

This invention relates generally to apparatus, systems and methods for modular furniture and large-scale play structures. More specifically, at least one embodiment, relates to a building system having ideal modularity.

2. Discussion of Related Art

Play building-sets with a fixed set of building components suitable for children to build structures are well known. Some of these building-sets do not use fasteners for assembly. Instead, they may employ sliding engagement in combination with some form of friction fit. For example, LEGO plastic building bricks include structure built into each building component that allows them to be secured to one another when they are aligned and pressed together. However, many other building-sets employ actual fasteners to assemble components. Among these, many different types of fastening systems are used. Some approaches require the use of tools such as allen wrenches or screw drivers to assemble the structures. Some include fasteners with two separate loose components that secure to one another. Others include a loose fastener in combination with a fastener-receiving element, for example, a receiving element built into a frame to which the building components are attached. In general, building systems that include separate fasteners fail to properly address the needs of users who are children because they require tools, other elements that are too difficult to use and/or do not support building structures that are truly modular.

Often, the play building-sets are referred to as modular because they can be employed to build multiple different structures with the same set of building components. However, many of the building-sets include a limited number of shapes and form factors that do not provide a universal solution for the needs of users. That is, the basic building components may have limited utility because the component shape includes built-in features, for example, a 90 degree bend that is only suitable in a limited number of building structures that require the shape. Similarly, the basic building components may not be assembled with a repeating unit of length or a multiple thereof because of the manner in which the basic building component is manufactured and also the manner in which the basic building components are attached to one another.

Traditional approaches are not truly modular because they cannot be used to build structures that maintain the repeating unit of length or multiple thereof as the dimensions of the structure are increased. For example, where panels are the basic building component in a building set they may have a known length L. Prior approaches do not permit multiple panels to be assembled into basic shapes such as squares, rectangles and shelves while maintaining the length of each side of the structure as a length L or L(N) where N equals a multiplier, for example, a positive integer.

Referring toFIG.1, a prior art structure100illustrates a fundamental problem found in prior approaches. The structure100is a set of shelves with a full length lower shelf and an upper shelf with two compartments that have equal dimensions. The structure is assembled using two types of panels. The first type of panel has a dimension that equals a length X. The second type of panel has a dimension that equals a length 2X. The structure100is assembled with four exterior sides. Both the top side and the bottom side are constructed from a respective panel with a length of 2X. The middle shelf is constructed with two panels with a length of X arranged side by side on their edge. The divider is constructed using a single panel with a length X orientated vertically between the middle shelf and the upper shelf. Each of the panels includes a thickness t.

Although each of the panels is provided with a length X or multiple thereof, the structure100cannot be constructed in a modular fashion with the panels. In particular, the panels engage with one another at right angles in a manner that causes the structure100to have dimensions of the height that are offset from one another. The offset increases as the size of the structure grows (i.e., as the structure is scaled). For example, the top shelf and the middle shelf together have an overall height of X+2t and a width of 2X. Thus, the height and width are not modular because they fundamentally differ from one another because, for example, the height is not a multiple of the unit of length X. That is, the height includes the offset dimension of 2t while the width does not include any offset value. As illustrated inFIG.1, the combined structure100also including the lower shelf in addition to the upper, and the middle shelves has an overall height of 2X+3t and a width of 2X. Here, the offset has increased from 2t to 3t with the addition of another level of shelving. The discrepancy increases further with an addition of further levels of shelving. The preceding cannot be employed to achieve modularity. For example, the continuing change in dimensions with the addition of each new level of shelving also creates a change in the spacing of some fastener locations relative to others that may be included in a series of panels included in a building structure.

SUMMARY OF INVENTION

Therefore, there is a need for apparatus, systems and methods that provide truly modular systems that include core components that are constructed in a standard unit of length or a multiple thereof. There is also a need to provide building systems that are truly universal. In the various embodiments described herein, these building systems give the user an opportunity to assemble a wide variety of different structures using the same set of components. Some of these embodiments allow the building systems to be assembled without the use of tools. That is, the components included in the building systems are fastened to one another with a tool-free fastener system. In further embodiments, the tool-free fastener system is employed in a building system that does not include any elements that are employed as framing or as a support structure for the components when assembled to one another. According to some embodiments, the components included in the building systems are fastened to one another with a tool-free fastener system including tool-free fasteners that are actuated by hand to secure building components to one another.

The embodiments described herein provide a consistent and repeated spacing of the locations for fasteners used to secure building components to one another. In addition, to provide an ideal modularity, these embodiments maintain the dimensions of building components and the separation distance between adjacent fastener locations as a multiple of one another. Further, the building components, such as panels include features as a part of each edge that allow for panels to be attached edgewise to one another at any angle within a predefined range of attachment-angles while maintaining the ideal modularity of the attached panels relative to one another.

In mathematics, a plane is a flat, two-dimensional surface that is infinitely thin. As used herein, the term “ideal plane” refers to a plane that is centrally located within a building component such as a panel. Applying the concept to hypothetical planar building components (i.e., an infinitely thin panel), components can be attached edgewise in the same plane in a consistent manner to build a structure having the same change in the overall dimensions of the modular structure with the addition of each panel. While the preceding may also be achieved with panels that have a thickness when laid side by side, it is not possible to maintain ideal modularity in the assembly of three dimensional structures. The preceding shortcoming is illustrated inFIG.1where an attachment of additional components above or below an existing shelf expands the dimensions of the structure further and further from the ideal.FIG.1illustrates that an attachment of prior art building components at 90 degrees relative to one another cannot be completed in a manner such that the three intersecting panels are attached at the intersection of the respective ideal planes. Instead, the panel that is perpendicular is secured to the other panel(s) offset by ½ the thickness of the other panel(s). Various embodiments overcome the shortcomings of prior approaches and allow panels to be attached to one another at a range of angles including 90 degrees at the intersection of the respective ideal plane associated with each. In further embodiments, the range of angles includes angles up to and including 180 degrees.

In further embodiments, these building systems provide apparatus, systems and methods with an ideal modularity. As used herein, “ideal modularity” refers to a building system that includes panels sized and shaped such that structures assembled with the panels increase in height, length and width with the addition of a panel above, adjacent to or attached at right angles to, respectively, an existing panel included in the assembly where the respective increase in height, length or width occurs in a repeatable unit of measure or multiple thereof and the unit of measure is a distance separating adjacent fastener locations in the panels. According to one embodiment, the respective increase in height, length or width is a positive integer multiple of the unit of measure.

According to some embodiments, ideal modularity is achieved by providing planar panels that include edges having opposing chamfers separated by a central planar region that runs both longitudinally and vertically along the panel-edge. According to some embodiments, chamfers allow building components to be attached to one another in a manner that maintains ideal modularity. For example, in one embodiment, chamfers allow building components to be attached to one another in a manner such that they are positioned at angle of less than 90 degrees at a location of their ideal planes.

According to one aspect a building system includes a plurality of panels having a thickness, a planar-quadrangle shape including a length, a width and four chamfered edges with a set of holes located along each edge, a plurality of fixed-location fastening elements located within the holes and a plurality of movable fastening elements. According to one embodiment, the plurality of panels includes four panels including a first panel, a second panel, a third panel and a fourth panel. Further, the holes are located at a fixed interval relative to one another, the fixed interval providing a unit of length. Each movable fastening element includes a hand-grip to allow the respective movable fastening element to be moved between an unsecured position and a secured position without the use of tools when received by any one of the plurality of fixed-location fastening elements. Further, the plurality of panels are configured to assemble at right angles such that four panels are secured together to form a hollow quadrangle-shaped structure when the assembled-panels are viewed edgewise. A distance measured from an outside plane formed by the first panel to an outside plane formed by the second panel provides a first dimension, the second panel located opposite the first panel in the structure. A distance measured from an outside plane formed by the third panel to an outside plane formed by the fourth panel provides a second dimension, the third panel located opposite the fourth panel in the structure, wherein each of the first dimension and the second dimension is an integer multiple of the unit of length.

According to another aspect, a method for building large-scale play structures having an ideal modularity is provided. According to one embodiment, the method includes providing panels having a thickness, a planar-quadrangle shape including a length, a width and four chamfered edges with a set of holes located along each edge, the holes located at a fixed interval relative to one another, the fixed interval providing a unit of length, a fixed-location fastening element located in each of the holes, respectively; providing a plurality of movable fastening elements each including a hand-grip to allow the respective movable fastening element to be moved between an unsecured position and a secured position without the use of tools when received by any one of the plurality of fixed-location fastening elements; and employing the fasteners to secure a plurality of the panels to one another to provide a structure that has an overall height, an overall length and an overall width, the structure including at least a pair of panels oriented one above the other and at least a pair of panels located at the same elevation and secured at right angles to one another. Further, the structure defines a hollow quadrangle-shape when the structure is viewed from above, and the overall height, the overall length and the overall width each provide a respective dimension that is an integer multiple of the unit of length.

Further, there is a need to provide the preceding building systems suitable for their safe use by children. In various approaches, these building systems provide the ease of use required for assembly by children independent of any adult supervision and also meet industry safety standards. In some embodiments, these approaches provide apparatus, systems and methods that comply with the “Standard Consumer Safety Specification for Toy Safety” provided by ASTM International. For example, embodiments provide for hinged attachment of adjacent building components that meets ASTM requirements for pinch clearance through the full range of hinge motion. Further, embodiments described herein provide a hinge structure that prevents unexpected lid-closure caused by gravity in a toy chest configuration. The preceding feature can prevent injuries that would otherwise occur.

DETAILED DESCRIPTION

Referring now toFIGS.2A-2C, a panel200is illustrated in accordance with one embodiment. In various embodiments, the panel200is included in a building system that allows users to build structures with dimensions that consistently maintain ideal modularity. In some embodiments, the panel200is included in a building system created for use by children to build large scale play structures. In other embodiments, the panel200is included in a building system created for use building adult-scale furniture.

The panel200includes a plurality of holes202, for example, through holes that are sized and located to receive fastening hardware. The panel200is provided in a quadrangle shape that has a length L and a width W. Although the illustrated embodiment is provided in a square shape, the panel200can also be provided in an overall rectangular shape. The panel200includes four edges in either embodiment. Referring toFIG.2B, a first edge203A, a second edge203B and a third edge203C are identified.

In various embodiments, the plurality of holes202are located along each edge where each hole is spaced a uniform distance apart from adjacent ones of the plurality of holes202. For example,FIG.2Billustrates a first hole202A, a second hole202B, a third hole202C and a fourth hole202D located adjacent to one another along the first edge203A. Each of the plurality of holes202A-202D are separated from adjacent holes along the first edge203A by a distance D. According to this embodiment, both the first hole202A and the second hole202D are located at respective corner locations. As a result of their location and the quadrangle shape of the panel200, the first hole202A is also located along the second edge203B adjacent a fifth hole202E and the fourth hole202D is also located along the third edge203C adjacent a sixth hole202F. Further, the first hole202A is separated from the fifth hole202E by a distance D and the fourth hole202D is separated from the sixth hole202F by the distance D.

Referring now toFIG.2C, a thickness T of the panel is illustrated in a view of the first edge203A of the panel200. The edge203A includes a first chamfer204, a second chamfer206, an intermediate section208, a first surface210and a second surface212. Each of the four edges includes the structure shown and described with reference to the first edge203A illustrated inFIG.2C.

According to the illustrated embodiment, the first chamfer204and the second chamfer206are symmetrically located on either side of a planar surface provided by the intermediate section208. In a further embodiment, the chamfers204,206are selected to support a building system that provides for assembled structures that have ideal modularity. In one embodiment, the chamfers204,206are provided at an angle relative to the adjacent surface210,212, respectively, that is equal to or greater than the most acute angle formed by any two panels when connected along adjacent edges to build a structure with the building system. For example, if the most acute angle formed by the panels of a building system is 60 degrees, then each of the first chamfer204and the second chamfer206are provided at a 30 degree angle. Similarly, if the most acute angle formed by the panels of a building system is 90 degrees, then each of the first chamfer204and the second chamfer206are provided at not more than a 45 degree angle.

Further, the depth to which the chamfers204,206are cut into the edge203can also be selected to provide panels that are attached to one another while maintaining an ideal modularity of structures built with the building system. For example, the panel thickness T equals one half inch and the most acute angle formed by the panels of a building system is 60 degrees. According to this embodiment, each of the first chamfer204and the second chamfer206are provided at a 30 degree angle to a depth of one quarter inch, respectively. Similarly, each of the first chamfer204and the second chamfer206are provided at a 45 degree angle to a depth of one quarter inch, respectively, for panels having a thickness T of one half inch used in building systems with a minimum connection-angle of 90 degrees. According to one embodiment, a panel having a thickness of ½ inch includes each of a first chamfer and a second chamfer cut to a depth of 0.2 inches. According to these embodiments, a plane extending from the first chamfer and the second chamfer, respectively, on each of a respective pair of panels fastened to one another as described herein intersect at the same location as the intersection of the ideal planes of the two panels.

As is described in greater detail below, the minimum connection-angle can be established based on the fastening hardware included in the building system. As one example, fixed angle brackets can be included to attach panels at a known angle. As another example, adjustable angle brackets or hinges can be designed to provide a limited range of motion that fixes the minimum connection-angle.

In further embodiments, the length L and width W of the panel202are also selected such that an ideal modularity is a result in the structures built with the panels202. According to one embodiment, the distance D is established as a basic unit of length on which panel dimensions L and W are based. In one embodiment, the panel length L and the panel width W are selected to be a multiple of the distance D, for example, an integer multiple. In other embodiments, the panel length L and the panel width W are selected to be a fractional multiple, for example ½D. In either embodiment, the basic unit of length is established to maintain the ideal modularity and the nominal dimensions of the panel202are also decreased by the panel thickness T. That is, both the length L and the width W are reduced by an amount equal to the panel thickness T. The preceding combination of features allows panels to be connected together to build structures that increase in size only by the basic unit of length or multiple thereof as building components are connected together. The embodiments described herein also allow building components to be connected at the intersection of their ideal planes. As is described in greater detail herein, this form of connection allows panels attached to one another by a hinge to move through a range of motion that includes the most acute connection-angle while maintaining ideal modularity.

According to the illustrated embodiment, the plurality of holes202are each sized to receive a respective fastening element, for example, a fixed-location fastening element in the form of a pair of inserts that are pressed into engagement with one another within a respective hole. According to the illustrated embodiment, each of the plurality of holes202have a constant diameter that extends from the first surface210to the second surface212. The fixed-location fastening element has an overall cylindrical shape such that it can be secured by one or a combination of a friction fit and adhesive within one of the holes202. As is described in greater detail herein, the fixed-location fastening element can be provided as a single component or two components that are secured together to form the fixed-location fastening element. Once in place, the fixed-location fastening element is positioned to receive a second moveable fastening element that engages structure included in the fixed-location fastening element to secure the two fastening elements together. For example, the fixed-location fastening element can receive and engage the distal end of the moveable fastener. As is described in greater detail herein, the type of fastener that is employed can vary depending on the embodiment. Thus, fastening components can include pins, screws, bolts and clamps. While the fastening components can include standalone elements such as the preceding, further embodiments can include these elements as an integral part of components that provide additional functionality such as brackets, hinges, clamps, furniture legs and handles as some examples.

Referring now toFIGS.3A and3B, a panel300is illustrated in accordance with another embodiment. The panel300includes a plurality of holes302. In various embodiments, the panel300is included in a building system that allows users to build structures with dimensions that consistently maintain ideal modularity. That is, structures assembled using the panels can be scaled by adding sections where each new section increases the overall dimensions of the structure by the same dimension or a multiple thereof. In some embodiments, the panel300is included in a building system created for use by children to build large scale play structures. In other embodiments, the panel300is included in a building system created for use building adult-scale furniture.

The panel300is provided in a quadrangle shape that has a length L and a width W. Although the illustrated embodiment is provided in a square shape, the panel300can also be provided in an overall rectangular shape. The panel300includes four edges in either embodiment. Referring toFIG.3A, an edge303is identified. According to the illustrated embodiment, the edge303includes symmetrical chamfers located on either side of a central planar region as illustrated and described with reference toFIG.2and the edge203A. Further, in various embodiments, the panel300includes the combination of features concerning the chamfer angle, the chamfer depth and panel dimensions described above concerning the panel200. According to these embodiments, a building system in which the panel300is employed provides an ideal modularity while increasing safety by avoiding or eliminating pinch points.

In various embodiments, the plurality of holes302are located along each edge where each hole is spaced a uniform distance apart from adjacent ones of the plurality of holes. For example, in the illustrated embodiment each of the plurality of holes302are separated from adjacent holes by a distance D. In some embodiments, the distance D establishes a basic unit of length for the building system in which the panel is included.

The panel300differs from the panel200because each of the plurality of holes includes counterboring. According to this embodiment, the fastening element located in each of the plurality of holes302, respectively, includes a flange at each end. The flanged regions are received within the counterboring to allow the fastener to sit flush with the surface310,312of the panel300.

As illustrated inFIG.3B, the hole302A includes a first fastening element313A, for example, a fixed-location fasting element, located in the hole302A. In general, the first fastening element313A includes structure that allows it to be securely located in the hole302A. Additionally, the first fastening element313A includes structure that allows a second fastening element (not shown) to be removably secured within the first fastening element313A. That is, a fastening element can be moved into engagement with the first fastening element313A to temporarily secure panels to one another during the process of building a structure from a set of building components that can include a plurality of panels such as the panel302, a plurality of second fastening elements that may include associated hardware such as brackets, hinges, legs and handles as some examples. A user can construct a customizable structure from these modular building elements. The user can later disassemble the structure by disconnecting the second fastening element(s) from the first fastening element(s) and build a completely different structure that also maintains ideal modularity.

The materials of construction can vary depending on the embodiment. According to one embodiment, the panel300is manufactured from wood and the fixed-location fastening element is manufactured from plastic. In another embodiment, the panel300is manufactured from plastic. According to this embodiment, the first fastening element described above can be molded within the respective holes. The preceding eliminates the need to manufacture separate components that must be located and secured within the holes.

The embodiments described herein provide a consistent and repeated spacing of the locations for fasteners used to secure building components to one another. In addition, to provide ideal modularity, these embodiments maintain the dimensions of building components and the separation distance between adjacent fastener locations as a multiple of one another. Further, the building components, for example, panels200,300include structural features on each edge that allow for panels attached edgewise to one another to move through a predefined range of motion while maintaining the ideal modularity of the attached-panels relative to one another.

The embodiments illustrated and described with reference toFIGS.2and3include panels with through-holes sized and configured to receive fastening hardware. In general, the fastening hardware includes a fixed-location element located in the through-hole (for example, an insert) and a movable fastener that is received in the fixed location element to secure a bracket to the panel. While the embodiments illustrated inFIGS.2and3are described with reference to a fixed-location fastening element that is secured in a fastener-hole202,302, other embodiments may provide the fixed-location fastening element formed as an integral part of the panel200,300. For example, in various embodiments, the panels200,300are manufactured from plastic and the fixed-location fastening element is molded into the panel during manufacture. This approach can reduce production costs by eliminating manufacturing and assembly steps needed where separate fixed-location fastening elements are employed in combination with the panels. According to these embodiments, the movable fastening is received in the fixed-location fastening element integral to the panel to secure a bracket to the panel200,300during assembly of building structure.

Various embodiments achieve the preceding and allow panels to be attached to one another at 90 degrees at the intersection of the respective ideal plane associated with each. As a result, the embodiments described herein maintain ideal modularity even where “T-connections” are made between panels. Referring toFIG.4A, a structure that provides the preceding is illustrated in accordance with one embodiment. The structure400includes a first panel420A, a second panel420B and a third panel420C. Depending on the embodiment, the panels420A,420B,420C can include embodiments illustrated and described with reference to the panel200or300ofFIGS.2and3, respectively. For clarity, fastening hardware is omitted inFIG.4A.

According to the illustrated embodiment, the second panel420B and the third panel420C are attached in a single plane adjacent to one another. The first panel420A is attached perpendicular to the panels420B,420C at a location where the second panel420B and the third panel420C are attached. A first ideal plane A associated with the first panel420A is illustrated along with a second ideal plane B associated with each of the second panel420B and the third panel420C.

Each of the panels420A-420C includes edges (for example, the edges403A,403B,403C, respectively) with the structure shown and described regarding the edges203and303illustrated and described with reference toFIGS.2and3, respectively. That is, the edges include a symmetrical chamfer located on either side of a central planar region that is perpendicular to the ideal plane.

As a result of the structure provided by the panels420A-420C, the T-intersection illustrated inFIG.4Aallows an edge of the first panel420A to be inserted between the second panel420B and the third panel420C in a manner that allows the panels to be attached to one another at an intersection of the ideal planes A and B.

The embodiment illustrated and described with reference toFIG.4also allow the panels420A-420C to be attached to one another at acute angles at the intersection of the respective ideal plane associated with each. Referring toFIG.4B, a structure401includes the first panel420A, the second panel420B and the third panel420C arranged in a polygon shape when viewed along the panel-edges. In particular, the structure401is illustrated in the form of an equilateral triangle with each of the first panel420A, the second panel420B and the third panel420C being of equal length. According to this embodiment, each angle formed by the structure401is a 60 degree angle. However, according to other embodiments, the polygon has a different shape and the acute angles will vary. For example, in one embodiment, the structure is an isosceles triangle that includes two 30 degree angles and a 120 degree angle. For clarity, fastening hardware is also omitted inFIG.4B.

According to the illustrated embodiment, the first panel420A is attached at an acute angle to each of the second panel420B and the third panel420C. The second panel420B is attached at an acute angle to each of the first panel420A and the third panel420C. Similarly, the third panel420C is attached at an acute angle to each of the first panel420A and the second panel420B. In each instance, the panels are attached at an intersection of the ideal planes, respectively, of the panels that are being attached. For reference, a first ideal plane A associated with the first panel420A and a second ideal plane C associated with the third panel420C is illustrated inFIG.4B.

As a result of the features included in the panels420A-420C, the panels can be attached to one another at an intersection of the ideal planes even at acute angles or obtuse angles. Thus, for example, the first panel420A and the third panel420C are attached to one another at an intersection of the first ideal plane A and the second ideal plane C.

Referring now toFIGS.5A and5Ba structure501is illustrated in an embodiment that includes ideal modularity. As illustrated inFIG.5A, the structure501includes a plurality of panels including a top panel500A, a first side panel500B, a first horizontal panel500C, a vertical divider panel500D, a second horizontal panel500E, a bottom panel500F and a second side panel500G. According to one embodiment, each panel500A-500G of the plurality of panels include the features shown and described with reference to the panel200ofFIGS.2A-2C. According to another embodiment, each panel500A-500G of the plurality of panels include the features shown and described with reference to the panel300ofFIGS.3A-3B. Here too, fasteners are omitted in the interest of clarity.

The structure provides a shelving structure with an overall polygon shape defined by the top panel500A the first side panel500B, the bottom panel500F and the second side panel500G. The first horizontal panel500C and the second side panel500E are aligned with one another in an edgewise fashion to provide a central shelf within the structure501. The vertical divider panel500D forms a T-intersection with both the top side of the central shelf and the underside of the top panel500A. In contrast to the prior art structure100ofFIG.1, in the illustrated embodiment, the building system provides for assembly of the structure501with ideal modularity. The preceding remains true regardless of the number of levels that are added to the structure501.

Referring toFIG.5B, dimensional features of the building system are described in accordance with this embodiment. Here, a basic unit of length D is established as a distance separating adjacent fastener holes along the edge of the panels, for example, as illustrated with reference to the panel500B. The length of each of the panels500A-500G is established as an integer multiple of the basic unit of length. The structure501includes a first panel-type with a nominal length equal to two times the basic unit of length. The structure501also includes a second panel-type with a nominal length equal to four times the basic unit of length. In addition, the edges of the panels500A-500G include a symmetrical chamfer. As a result of the chamfers, a small gap is provided at an intersection between panels. The gap allows the panels to be aligned and fastened together such that their ideal planes intersect. For example, the T-intersection formed by the first horizontal panel500C, the second horizontal panel500E and the vertical divider panel500D allows the vertical divider panel500D to be inserted between the respective ends of the first horizontal panel500C and the second horizontal panel500E and fastened together at an intersection of the respective ideal planes of each.

Referring now toFIG.6, a building system600including an attachment of building components is illustrated in accordance with one embodiment. The building system600includes a first panel620A, a second panel620B and connecting hardware624.FIG.6illustrates a side view along a first edge603A of the first panel620A and a first edge603B of the second panel620B. A first ideal plane A is associated with the first panel620A and a second ideal plane B is associated with the second panel620B.

The connecting hardware624includes a first flange626A, a second flange626B, a first neck627A, a second neck627B and a hinge barrel628.FIG.6also illustrates handles648A and648B included in the fasteners associated with the first flange626A and the second flange626B, respectively. The fasteners are illustrated and described in greater detail below. The connecting hardware624can be manufactured of plastic, metal or other material that has sufficient mechanical strength and stiffness to maintain the panels620A,620B in a desired angular relationship to one another and support weight as required for use in the overall modular structure in which it is employed.

The connecting hardware624includes the first flange626A attached to the hinge barrel628by the neck627A and the second flange626B attached to the hinge barrel628by the neck627B. The first flange626A is attached to the first panel620A and the second flange626B is attached to the second panel620B, for example, using fasteners that include the handles648A,648B, respectively. According to the illustrated embodiment, the necks627A,627B are thinner than the flanges626A,626B. This approach makes more space available in the region between the necks627A,627B as the first flange626A and the second flange626B along with the attached hinge barrel are rotated about the axis of the hinge through a range of motion that reduces the angle between the first panel620A and the second panel620B. According to some embodiments, the connecting hardware624is employed in large scale play furniture assembled by children. In these embodiments, the connecting hardware provides improved child safety.

According to another embodiment, the fastening hardware624does not include the hinge barrel628. Instead, the fastening hardware624is a fixed-angle bracket with the flanges626A,626B attached to one another at a fixed angle at the intersection of the first ideal plane A and the second ideal plane B.

In various embodiments, the hardware shown and described with reference toFIGS.2-6is included in modular building sets for construction of large scale play structures by children. According to these embodiments, the structures are assembled with ideal modularity such that all panel dimensions and all fastener-hole spacing are multiples of a basic unit of length and the panels are connected in a manner that provides ideal modularity. Referring now toFIGS.7A and7B, a building structure700is illustrated in accordance with one such embodiment. According to this embodiment, the building structure700is a castle. However, the modular building systems described herein can include a wide variety of building components to facilitate an assembly of a large number of different building structures, including custom structures.FIG.7Aprovides a front view of the building structure700.FIG.7Bprovides a side view of the building structure700.

According to one embodiment, a basic unit of length D is established for a variety of different building components included in a building system that allows for the assembly of the building structure700and others. For example, the building components can include panels that have different dimensions (length and width) where all of the dimensions are an integer multiple of the basic unit of length D. For example, inFIGS.7A-7B, a height of the vertical panel used to form the front wall of the structure700is eight times the basic unit of length D. As illustrated inFIG.7B, the sides of the structure700include single panels that are 8D in length and 4D in width. The sides of the structure700also includes panels stacked on edge one above the other each panel being 4D by 4D. The structure has a depth of 8D as a result. Accordingly, the top side panels that include a decorative embattlement are 8D in length.FIG.7Aillustrates two top front panels each 6D in length and including decorative embattlements formed on their upper edge. Depending on the embodiment, accessories may not include dimensions that conform to ideal modularity. For example, the panels including decorative embattlements illustrated inFIGS.7A and7Beach have a height that is not a multiple of the basic unit of length D. Other accessories can be modified similarly especially in other examples where they primarily serve a decorative purpose.

The approaches described herein can employ a variety fastening hardware and fastening holes depending on the embodiment. Referring now toFIGS.8A and8B, a fastening system including fastening hardware is illustrated in accordance with a first embodiment. The illustration intentionally omits the panels with which the fastening hardware is used to better illustrate the features of the fastening hardware. The fastening hardware includes a fixed-location fastening element813and a fastener830. According to some embodiments, the fixed-location fastening element813is provided when a first insert814and a second insert815are pressed into a locking engagement with one another in a hole (for example,202,302,1202) in a panel.FIGS.8A and8Balso include a bracket832used to attach two adjacent panels to one another in a larger building structure. In contrast to the fixed-location fastening element813, the fastener830is a movable fastener because it is associated with the bracket832which can be used in any of a variety of building structures. That is, the fastener830and bracket832can be employed to assemble a series of building structures that are built and disassembled after a period of use. For example, the bracket832can be used with a first pair of panels in the assembly of a first large-scale play structure. The bracket832can be disconnected from the first pair of panels when the user decides to disassemble the first large-scale play structure and assemble a second large-scale play structure that is completely different. Here, the fastener830and bracket832may be used with the same pair of panels or two different panels. According to one embodiment, the fastener830is secured to the bracket832. Further,FIG.8Aillustrates the fastener830as a first fastener associated with the bracket832and also a second fastener831associated with the bracket832. The bracket includes a first flange826A and a second flange826B.

According to the illustrated embodiment, the fixed-location fastening element813includes a first annular flange834and a second annular flange836. The annular flanges834,836each include a plurality of cutouts835spaced around the radially outer edge of the flanges834,836, respectively. According to the illustrated embodiment, the first flange834is included in the first insert814and the second annular flange836is included in the second insert815. The fasteners830,831include handles respectively that allow a user to easily grip the fastener and rotate it between the unlocked and unlocked position.FIG.8Aillustrates a portion of a handle848of the second fastener831. The bracket832includes a plurality of ribs837located on the surface of the flange that is placed in contact with a building panel when the bracket is secured to the panel. According to the illustrated embodiment, the plurality of cutouts835are formed to receive a proximate end of a rib837. In the illustrated embodiment, the ribs are provided in varying lengths such that a single rib of the plurality of ribs is engaged with the fixed-location fastening element813when the fastener830is secured to the fixed-location fastening element813. That is, a proximate end of the leftmost rib837inFIG.8Ais secured within a corresponding cutout835. In operation, the engagement of the two components secures the bracket in a fixed rotational position relative to the fixed-location fastening element813. Because the fixed-location fastening element813is secured in a fixed rotational position in the panel, this feature results in the flange826A being in a fixed rotational position relative to the panel. According to further embodiments, multiple ribs included in the plurality of ribs837engage corresponding cutouts835.

In operation, the fixed-location fastening element813is secured within a fastener hole included in a panel, for example, as illustrated with reference to the panel1200and the plurality of holes1202illustrated inFIG.12. The design of the fastening system is such that the fixed-location fastening element813remains in a fixed rotational position within the panel. To secure the bracket to a panel, a distal end of the fastener830is inserted within the fixed-location fastening element813and the fastener830is rotated to a locked position to secure the fastener and associated bracket832to the fixed-location fastening element813. Referring toFIG.8Bfurther details of the fastener831are illustrated. The fastener831includes a locking member842, a central post844and a stop846that are provided in an integral fastener that also includes the handle848.

FIG.9illustrates a cross-sectional view of the fixed-location fastening element813, the fastener830and the bracket832ofFIG.8. According to the illustrated embodiment, the fixed-location fastening element813includes the first annular flange834, the second annular flange836, the central region838, a hollow region839and a pair of extensions840. The fastener830includes the locking member842, the central post844, the stop846and the handle848. In general, the fastener830is oriented in a first rotational position, inserted to a predetermined depth within the fixed-location fastening element813and rotated to engage the fastener830with the fixed-location fastening element813to secure the fastener to the fixed-location fastening element813. InFIG.9, the fastener830is shown in the fastened position in which it is securely attached to the fixed-location fastening element813. The result of the preceding operation is to secure the first flange826A associated with the bracket832to the panel in which the fixed-location fastening element813is installed.

The first annular flange834is located at a first end of the fixed-location fastening element813and the second annular flange836is located at a second end opposite the first. The central region838connects the two flanges834,836to one another. According to the illustrated embodiment, the central region838has a smaller diameter than the two flanges834,836. The hollow region839has an overall cylindrical shape and extends from the first end of the fixed-location fastening element813to the second end of the fixed-location fastening element813. That is, a portion of the hollow region839is located within each of the first annular flange834, the second annular flange836and the central region838. The pair of extensions840extend radially inward into the hollow region839from a cylindrically-shaped interior wall that defines the hollow region839. According to the illustrated embodiment, the pair of extensions840is not annular. Instead, a first of the pair extends for a limited amount of the circumference of the hollow region839, for example, for 45 degrees or less. A second of the pair extends opposite the first of the pair of extensions. Further, the pair of extensions840defines a narrowed region841within the hollow region839. As described in greater detail below, the pair of extensions840aid in securing the fastener830to the fixed-location fastening element813when the fastener830is inserted within the fixed-location fastening element813and rotated to a secured (or “locked”) position.

As illustrated inFIG.9, some features provided in the first insert814and the second insert815, respectively, are combined with the two inserts coupled to one another to provide the overall internal structure of the fixed-location fastening element813. That is, each of the central region838, the hollow region839and the pair of extensions are provided as a result of the combined features of the two inserts814,815. For example, the hollow region839extends from an opening defined by the first annular flange834to an opening defined by the second annular flange836via a cylindrical hollow region located within the first insert814and a cylindrical hollow region located within the second insert815. Similarly, the overall structure of the pair of extensions840is provided by the combination of a first pair of extensions included in the first insert814and a second pair of extensions included in the second insert815.

The central post844and the locking member842define a general t-post shape that is included at the distal end of the fastener830. The handle848is located at a first (or proximate end) of the fastener830. The central post844connects the locking member842to the stop846which is located approximately midway between the handle848and the locking member842. According to the illustrated embodiment, the locking member842is defined by two walls substantially parallel to one another that provide the locking member842with a generally rectangular shape that has a length that is greater than the diameter of the central post844. The stop846is provided as an annular extension for 360 degrees about the longitudinal axis of the fastener830. The stop846has a diameter that is greater than diameter of the central post844. According to one embodiment, the length of the locking member842and the diameter of the stop846are substantially equal. According to a further embodiment, the length of the locking member842and the diameter of the stop846are sized to be slightly smaller than the diameter of the hollow region839.

As described in more detail with reference toFIG.11, the fixed-location fastening element813is fully received within a fastener hole, for example, in a panel200,300,1200. According to one embodiment, an outer surface of the first annular flange834is flush with a first side of the panel and an outer surface of the second annular flange836is flush with a second side of the panel. According to an alternate embodiment, the outer surface of the first annular flange834is raised above the first side of the panel and the outer surface of the second annular flange836is raised above the second side of the panel with the fixed-location fastening element813fully received within a fastener hole of a panel. According to the latter embodiment, the fastener holes in which the fixed-location fastening element813is received do not include any countersinking because it is unnecessary where the flanges834,836are not recessed within the panel, for example, as described in greater detail below.

In any of these embodiments, the fixed-location fastening element813is secured in a fixed rotational position when fully received within the fastener hole. The user grasps the handle848and then inserts a distal end of the fastener830into the fixed-location fastening element813while moving the attached bracket832into engagement with a surface of the panel, and in some embodiments, a surface of the insert. Still grasping the handle848the user rotates the fastener830to rotate the locking member842so that it is perpendicular to the position of the narrow region841between the pair of extensions840. The fastener830is inserted in the fixed-location fastening element813until the distal face of the stop846contacts the pair of extensions840. The fastener830is now fully inserted in the fixed-location fastening element813. The user rotates the fastener83090 degrees to place the fastener830in the secured position illustrated inFIG.9. In the secured position, the rotational position of the fastener830aligns the locking member842with the pair of extensions840. The result of this operation is that the fastener830is now secured within the fixed-location fastening element813and the bracket832is secured to the panel in which the fixed-location fastening element813is installed. The user can later disassemble the connection by either reversing the original direction of rotation to return the fastener830to the original unsecured position or continuing the original direction of rotation another 90 degrees. Each of the preceding acts to release the fastener830from engagement with the fixed-location fastening element813.

In various embodiments, the bracket832and the fastener830are attached to one another such that they cannot be easily separated by users, for example, attached to one another prior to the building system being shipped to the consumer. According to these embodiments, the fastener830remains free to rotate between the secured and the unsecured position while remaining attached to the bracket832. According to the illustrated embodiment, the assembly includes a retaining ring (or “C-clip”)849that secures the fastener830to the bracket832. For example, the retaining ring849can be slid around the shaft of the fastener830once it is inserted within a hole in the bracket832. Once the fastener830is placed in secure engagement with the bracket832, the axial motion of the fastener830relative to the bracket832is constrained by the attachment with the retaining ring849.

According to some embodiments, the fixed-location fastening element813is a two piece unit with the first insert814inserted in a fastener-hole from a first side of a panel and the second insert815inserted in the same fastener-hole via a second side of the panel. As illustrated inFIG.10, the second insert815includes at least one projection852, a planar surface853, at least one receiving opening854and at least one rib856. In further embodiments, the second insert815includes a plurality of projections852, a plurality of planar surfaces853, a plurality of openings854and a plurality of ribs856. The insert also includes a first arm855A and a second arm855B. The arms855A,855B each include a hook857A,857B located at a distal end of the arms855A,855B, respectively. According to these embodiments, the first insert814includes similar structure.

According to the illustrated embodiment, a pair of ribs856A,856B included in the second insert815define a slot configured to receive a hook857A,857B, respectively, included in the first insert814. A ledge859A is located in the slot or region between the pair of ribs856A,856B. A second ledge859B is also visible between a second pair of ribs856C,856D inFIG.10. According to the illustrated embodiment, each ledge includes a ramp-like surface.

A complete fixed-location fastening element813is assembled by pushing the second insert815into engagement with the first insert814in an axial direction with the projections852of the first insert814aligned with the corresponding openings854included in the second insert815and vice versa. That is, the rotational position of the two inserts must be established such that the projections852and the openings854included in the second insert815align with corresponding elements included in first insert814. That is, the projections852included in the second insert815align with openings included in the first insert814. Similarly, the openings854included in the second insert815align with projections included in the first insert814.

According to some embodiments, the arms855A,855B are resilient, that is, they are capable of flexing in a radial outward direction and later returning to their normal static position. With the proper rotational alignment of the two insert as described above, the arms855A,855B are aligned with corresponding slots in the first insert814. When the two inserts are pressed together, the distal end of the arms855A,855B are deflected in a radial outward direction as the hook857A,857B engages the corresponding ledge859included in the first insert814. However, with the two inserts fully-pressed together, the distal end of the two arms855A,855B move beyond the ledges such that the radially outward force on hooks857A,857B is removed. That is, the pressing-engagement between the ramp of the ledge and the hook is relieved. At this stage, the resilient arms deflect radially inward in the direction of their static state such that the hooks857A,857B are captured on the underside of the corresponding ledge859A,859B.

According to some embodiments, adhesive is applied to either or both of two halves when they are inserted into the fastener opening. For example, adhesive can be applied to either or both of the faces on each half where the projections are located and to the radially outer surfaces of the two halves. The plurality of ribs856also provide a friction fit of the fixed-location fastening element813within the fastener opening. For example, where the fixed-location fastening element813is manufactured from a material that is harder than the material of manufacture of the panel, the ribs can deform grooves into the inside walls of the fastener holes. According to one such embodiment, the fixed-location fastening element813is manufactured from plastic such as polypropylene, ABS or nylon and the panel is manufactured from wood.

According to some embodiments, the plurality of holes202,302,1202included in the panel have a generally rectangular shape, for example, including rounded corners. The preceding is described in greater detail below with reference toFIG.12. According to these embodiments, the fixed-location fastening element813has an overall shape that closely corresponds to the non-circular shape of the hole. The preceding combination of features can be employed to maintain the fixed-location fastening element813in a fixed rotational position when secured in the hole. According to these embodiments, the planar surface853is located on opposing sides of each insert814,815. These “flats” provide a surface that is configured to engage the long-side of the generally rectangular-shaped hole and assist in properly orienting the insert in the hole.

Referring now toFIG.11, a combination of the fixed-location fastening element813, the fastener830and the bracket832are illustrated in use with a panel1100. The panel1100includes a plurality of fastener-holes (not illustrated). In the illustrated embodiment, the bracket832includes two flanges separated by one another by 90 degrees. When attached to adjacent panels, the bracket832secures the panels at right angles to one another. The bracket832is secured using two fasteners830A and830B. Each fastener is as illustrated and described with reference toFIG.9. For example, the fasteners830A,830B each include a locking member, a central post and a stop.

In some embodiments, the length of the central post844is established, at least in part, to prevent the distal end of the fastener830from extending beyond the exterior surface of the flange. The outside diameter of the central region838is established to provide an interference fit within the hole. For example, in one embodiment, the overall shape of the inserts814,815can include a taper with an increasing outside diameter when moving outward from a midpoint of the fixed-location fastening element813in an axial direction toward one of the respective annular flanges834,836. In the illustrated embodiment, the exterior surfaces of the annular flanges834,836are raised above the surface of the panel and the distal end fastener830is flush (or in some embodiments, slightly recessed) relative to the exterior surface of the flange and/or the panel.

Referring now toFIG.12, a first panel1200A and a second panel1200B are attached to one another at right angles using the bracket832, the first fastener830A and the second fastener830B. The attachment positions panels1200A,1200B at an intersection of the ideal plane of the first panel1200A and the ideal plane of the second panel1200B. According to the illustrated embodiment, each fastener830A,830B includes a handle1248A,1248B, respectively. The handles1248includes an extension (or “tail”) that extends radially in one direction from the longitudinal axis of the fastener830. The extension increases the user's leverage when moving the fastener830between the released position and the secured position.

FIG.12also illustrates an embodiment that employs a plurality of fastener holes1202. According to the illustrated embodiment, the plurality of holes1202are each sized to receive a respective fastening element in the form of an insert. According to this embodiment, each of the plurality of holes1202has an overall non-cylindrical shape. In particular, each of the fastener holes1202has an overall rectangular shape with a radius at each corner. This shape can, for example, be employed with the fixed-location fastening element813illustrated and described with reference toFIGS.8-10. The fixed-location fastening element813can also be secured by one or a combination of a friction fit and adhesive within one of the holes1202. As is described in detail herein, the fixed-location fastening element813can be provided as a single component or two components that are secured together to form a fixed (or stationary) fastening element.

Referring now toFIGS.13A and13B, a hinge1300is illustrated in accordance with one embodiment. According to the illustrated embodiment, the hinge1300includes multiple components including a first flanged connector element1363, a second flanged connector element1364, a third flanged connector element1365, a fourth flanged connector element1366and a hinge pin1368. The hinge pin1368includes a central region1370, a first end region1372and a second end region1374. The flanged connector elements1363,1364,1365,1366each include the flange with a fastener1330coupled to the flange, respectively, for example, with a C-clip. Each flanged connector element also includes a first hollow cylinder1382and a second hollow cylinder1384, for example, as identified inFIG.13Bin association with the fourth flanged connector element1366.

FIG.13Bprovides an exploded view of the hinge1300. According to one embodiment, the central region1370is included in a single piece of material that defines the hinge pin1368but with a diameter that is greater than the diameter of the respective first end1372and second end1374. According to another embodiment, the central region1370is a hollow tube that is secured in an axial location on a fixed diameter pin that includes the first end1372and the second end1374. The first end1372and second end1374have diameters that are sized to allow them to be inserted within the respective hollow cylinders1382,1384that they engage with to assemble the hinge. The hinge1300is assembled by moving the first flanged connector element1363and the second flanged connector element1364into engagement such that the respective hollow cylinders associated with each are aligned to form a single cylinder. The first end1372is inserted within the cylinder. The third flanged connector element1365and the fourth flanged connector element1366are moved into engagement with one another in a similar fashion to form another cylinder. The second end1374is inserted in the cylinder formed by the third flanged connector element1365and the fourth flanged connector element1366.

In some embodiments, the hinge1300includes multiple features that improve the safety of the building structures in which it is included. A toy chest and other structures include a hinge having a hinge pin located in a horizontal axis. The lid is raised upwards to open the toy chest and lowered to close the toy chest. According to various embodiments, the hinge1300can include structures that prevent a panel from free falling as a result of gravity. In one embodiment, the hinge1300includes a plate with a series of serrations, that is, a pattern of alternating raised and lowered features included in an otherwise flat surface. In this embodiment, a corresponding arm includes a projection or protrusion included in the face that engages the plate. The contact between the serrations and the protrusions creates friction when the panels are moved relative to one another. In one embodiment, a single protrusion located on the arm fits into a series of recessions included in the panel to support the panel in various open positions in the manner of a non-locking detent. Another embodiment includes a ball bearing mounted on one hinge half which presses against a plate on the second hinge half and fits with sufficient force such that gravity alone cannot cause the panel to fall.

In addition, the length and the diameter of the central region1370also increases the safety of structures that include the hinge1300. In general, operation of a hinge to swing the panels further apart results in a pinch point being created along the hinge line as the hinge line opening decreases in size. However, in the illustrated embodiment, the central region1370spans the distance that separates the two hinge assemblies. In addition, the diameter of the central region1370is large enough to fill the hinge line such that the pinching hazard is eliminated.

Referring now toFIG.14, a fastener system1400is illustrated in accordance with a second embodiment. The fastening system1400includes a first element1485and a second element1486that are located on opposite sides of a panel and secured to one another via a rotational movement of the second element1486relative to the first element1485. According to these embodiments, the panels include fastener-holes that are through-holes. The first element1485includes a body with an overall rectangular shape and a cylindrical projection and a corresponding t-post projection located on each of two sides, respectively, that are adjacent to one another. In the illustrated embodiment, the fastener system1400is configured to attach two panels connected at right angles to one another at an intersection of the respective ideal plane of the two panels. Accordingly, each edge of the body of the first element1485includes a chamfer.

The second element1486includes an overall planar shape with a through hole located at one end. The through hole includes structure to receive the t-post of the first element1485when oriented in a first position. The second element1486is then rotated 90 degrees to secure the t-post in the opening, and a result, secure the first element1485and the second element1486to one another on opposite sides of a panel. To attach two panels together at 90 degrees, the other t-post included in the first element1485is inserted through a fastener hole of the adjacent panel and secured thereto using another second element1486.

Referring now toFIG.15, a fastener system1588is illustrated according to a third embodiment. The fastening system1588includes a first element1590, a second element1592and a third element1594. According to this embodiment, the fastener-hole is replaced with a fastener-notch integral with the panel-edge. In the illustrated embodiment, the fastening system1588is employed with panels that have edges that include symmetrical chamfers located on either side of a central planar region. The fastener notches are located along each edge spaced at a fixed interval equal to the basic unit of length or multiple thereof. In general, the fastener system1588employs an externally applied fastener that engages a corresponding element located in a notch in each of the panels, respectively.

The first element1590and the second element1592are identical components. Each includes a U-shaped base flange that is formed to be received within a notch cut into a panel edge. Projections extend outward from the base flange within the region defined by the U-shaped flange. In the illustrated embodiment, the third fastening element1594has a central region that sweeps in a 90 degree bend, a first opening located at a first end and a second opening located at a second end. Structure suitable for interlocking engagement with the projections included in the elements1590,1592are located in each of the openings. In use, the two panels are placed at a 90 degree angle with the first element1590and the second element1592already located in the notches of the respective panels. The third fastening element1594is located to align the first opening with the first fastening element1590and the second opening with the second fastening element1592. The third fastening element1594is then pressed into engagement with the fastening elements1590,1592to secure the panels to one another. In the illustrated embodiment, the fastener system1588is configured to attach two panels at 90 degrees to one another at an intersection of the respective ideal plane of the two panels. Other connection angles can be achieved while maintaining an attachment at the ideal planes by providing the third element1594with a different angle between the two ends.

Referring now toFIGS.16A-16B, a fastening system1600is illustrated according to a fourth embodiment. The fastening system1600is employed with panels that have edges that include symmetrical chamfers located on either side of a central planar region. The fastening system1600includes a first element1694and a second element1696. Fastener notches are located along each panel-edge spaced at a fixed interval equal to the basic unit of length or multiple thereof. In general, the fastener system1600employs an externally applied fastener that includes a keyhole, the first element1694, with an externally applied fastener that includes a pin, the second element1696, located on the opposite side of the panel. A sliding motion is employed to interlock the two elements once engaged. In the illustrated embodiment, the fastener system1600is configured to attach two panels connected at right angles to one another at an intersection of the ideal plane of each of the respective panels.

The first element1694includes a body that includes three sides oriented in the manner of a parallelogram but having chamfered corners where the edges meet. The remaining sides locate a symmetrical chamfer about a central planar region that includes the keyhole. At least a portion of the interior of the first element1694is hollow. The second element1686includes two flanges located at right angles to one another. The interior face of each flange includes four alignment pins. A central planar region that connects the two interior faces at angle includes a pin with a head sized and configured to insert within the keyhole while being secured therein when the first element1694is moved relative to the second element1696.

In operation, second element1696is pressed into engagement with two panels located at right angles. This is accomplished by locating the second element1696such that the alignment pins are aligned with corresponding holes included in the panel. In this position, the pin extending from the central planar region protrudes through the notch. Engagement of the alignment pins acts to maintain the second element1696in a fixed position relative to the first element1694as the first element is moved to secure the pin in the keyhole.FIG.16Billustrates a cross-sectional view in a plane perpendicular to a first element1694and a second element1696that secure two panels to one another at their ideal plane.

Referring now toFIGS.17A-17B, a fastening system1700is illustrated according to a fifth embodiment. The fastening system1700is employed with panels that have edges that include symmetrical chamfers located on either side of a central planar region. The fastening system1700includes a first element1720and a second element1722. Fastener notches are located along each panel-edge spaced at a fixed interval equal to the basic unit of length or multiple thereof. In the illustrated embodiment, the fastener system1700is configured to attach two panels connected at right angles to one another at an intersection of the ideal plane of each of the respective panels.

The first element1720includes a first winged flange that sweeps in a ninety degree bend. A pin is fixed in a central location on the flange extending perpendicularly from the flange. A lever operated clamp is located at the distal end of the pin. In a released position, the clamp extends in a direction substantially parallel to the pin. In a secured position, the clamp extends substantially perpendicular to the pin. The second element1722is a second winged flange that is similar in shape but smaller than the first winged flanged. A central region of the second element1722includes a hole that allows the second element1722to slide along the shaft.

In operation, the first element1720is inserted in a notch formed by two adjacent panels. As a result, the pin extends through the notch to the far side of the panels. The first winged flange is engaged with the surface of the two panels. The second winged flange included in the second element1722is engaged with the opposite surface of the two panels with the panels oriented at right angles to one another. The lever is moved from the released state to the secured state. The preceding operation presses the second winged flange into engagement with the surface of the two panels. The remainder of the lever motion draws the first winged flange and the second winged flange toward each other from opposite sides of the panel. The panels are securely pressed between the flanges when the lever reaches a fully secured position.

Referring now toFIG.18, a fastening system1800is illustrated according to a sixth embodiment. The fastening system1800includes a first element1801and a second element1803. Fastener notches are located along each panel-edge spaced at a fixed interval equal to the basic unit of length or multiple thereof. In the illustrated embodiment, the fastener system1800is configured to attach two panels connected at right angles to one another at an intersection of the ideal plane of each of the respective panels. In various embodiments, different brackets can be provided to secure adjacent panels at right angles, in a planar configuration or a hinged configuration.

The first element1801includes a pin including a head, a shaft and a groove located in the shaft. The head has an outside diameter that is greater than diameter of the fastener holes located in the panel. The second element1803is a bracket with two flanges including slots. The width of the slots is sized to correspond to the reduced diameter of the pin in the region of the groove. The groove in the pins is sized to receive the bracket. In the illustrated embodiment, the first element1801and the second element1803are separate from the panels. In the illustrated embodiment, the fastening system1800is configured to attach two panels connected at right angles to one another. According to this embodiment, the brackets include two flat surfaces oriented at right angles to one another. That is, the brackets are corner brackets. According to one embodiment, the panels can be connected at an intersection of the ideal plane of each of the respective panels.

The connections between the bracket and the panels are completed by inserting a respective first element1801in a fastener hole in the panels to be attached. The slots in the second element are aligned above the distal end of the pin. The second element is slid along a face of the panels to capture the bracket at the slot within the respective pins. The connection can be disassembled by proceeding in the reverse order to release the pins from the keyholes.

Referring now toFIGS.19A-19B, another fastening system1900is illustrated according to a seventh embodiment. The fastening system1900includes brackets with steel pins that extend at right angles to respective flanges included in the bracket. Panels include keyhole slots separated by the distance that separates the pins. Different brackets can be provided to secure adjacent panels at right angles, in a planar configuration or a hinged configuration.

To assemble a structure using the fastening system1900, adjacent panels are oriented in the desired configuration. The appropriate bracket is aligned such that the slots in the panels line up with a pin included in the bracket, respectively. The panels are secured together when the pins are seated in the respective slots using a sliding motion.

When employed in large scale play structures for children, the embodiments described herein provide for highly customized configurations that can evolve with a child as s/he grows, takes on new interests and gains skills. The customization can be supported through a number of different materials that might be used with these embodiments. For example, the panels and other components can be manufactured from plywood, solid wood and plastic. The building systems can include fabric, and removable/reusable self-adhesive fabric decals to allow for a further customized aesthetic design. The customization allows a child and parent to decide if they'd like to engage in truly open-ended play or not, and gives them ownership over the direction of their play. Removable and reusable fabric decals can give configurations a more specific look, such as the appearance of a stove burner, front loader washer/dryer, an oven, stones on a castle, or the side of a food truck. Decals not only provide customization in terms of objects or themes, but also in terms of color schemes. Smaller wood panels and furniture feet allow for a system to physically grow with a growing child, giving the product longevity. Depending on the embodiment, suction cups or separate t-post fasteners can be used to attach door handles, knobs, faucets and other smaller accessories to the structures, giving a child ownership over the location, appearance and functionality of their configurations. Select panels painted with a white board/dry erase or blackboard finish allow children to further customize their creations.

Referring now toFIG.20, an example of a large scale play structure is illustrated. According to this embodiment, the structure is assembled using the building components and fastening hardware illustrated and described with reference toFIGS.3A,3B and8-13B. Accordingly, the large scale play structure illustrated and described with reference toFIG.20maintains ideal modularity.FIG.20illustrates a kitchen set2000including a stove top, sink, cabinets and backsplash. According to some embodiments, the legs included in the kitchen set include a T-post structure that allows the legs to be attached to the panels in the manner shown and described with reference to the fastening system illustrated and described with reference toFIGS.8-11. According to some embodiments, the fastening hardware for accessories does not include a handle. Instead, the user grasps the accessory (for example, the leg) to rotate the accessory into a secured position.

Although the preceding is primarily described in the context of large scale play structures, those of ordinary skill in the art will understand in view of the disclosure herein that the embodiments of the building systems can be employed to assemble furniture having an ideal modularity. For example, embodiments of the panels and fastener systems illustrated and described herein can be employed to assemble tables, chairs, shelves, cabinets and other furniture having an ideal modularity. These building systems can be provided in kits that allow a user to assemble a first piece of furniture that can be modified with the addition of the other building components (panels and fastener) included in the kit. The first piece of furniture can be disassembled and the building components redeployed to build a second different piece of furniture that has ideal modularity.