CONSTRUCTION SYSTEM

A construction system has rods and connectors that may be assembled and disassembled in order to be re-used to construct a variety of geometric figures and other figures. Each connector has a plurality of sockets configured to form joints with the rods. Each socket has a cavity where the cavity has aligned openings. The socket at one of the openings forms an interference fit with an inserted rod.

BACKGROUND

Numerous construction kits and systems exist in the conventional art, each aimed at enabling the creation of various structures, both large and small. Many available sets, however, are constrained in scope, meaning that the structures that can be made are limited, and they are also difficult either to assemble or disassemble, sometimes both. In particular, sets for the construction of models sometimes do not offer the flexibility that enables the construction of an array of shapes and figures. That is, existing construction sets frequently lack the adaptability needed to construct diverse geometric figures. In addition, some sets suffer from structural weaknesses, causing rapid wear and reducing the lifespan of the components. Further, the assembly and disassembly processes might exert undue force on the components, leading to strains and handling difficulties. Since the purposes of many of these construction sets include inspiration and joy as well as learning, a construction set that is difficult and unpleasant to use is undesirable.

For the foregoing reasons, there is a need for in improved construction set configured to enable the construction of a wide array of structures, the construction set having parts that are easily assembled and disassembled.

SUMMARY

The present invention is directed to a rod and joint construction set configured for assembling diverse geometric figures like tetrahedrons, cubes and icosahedrons. The innovation focuses on providing a versatile, engaging, and educational construction system that encourages creativity, spatial understanding and structural exploration. The present rod and joint construction set aims to address the limitations described above in conventional construction systems. A benefit of embodiments of the construction set, that is, a set having connector sockets, double-ended rods with tapered pointed ends, and of the interaction between the sockets and inserted rods is that a large amount of variation in size and shape of both rods and sockets can be tolerated without affecting the correct operation of the construction system. Therefore, both the connectors and rods can be manufactured at a lower cost relative to conventional connector and rod construction systems that require accurate parts and high tolerance manufacture for correct operation.

Embodiments of the present construction system provide a solution that enables the assembly of various geometric figures with ease and structural integrity. The innovative design reduces force during assembly and disassembly, ensuring a longer lifespan for the components while promoting exploration and creative construction.

A first objective of embodiments of the present invention is to have a construction set that is material-efficient, inexpensive and easily mass-produced from a variety of materials using a variety of manufacturing techniques, e.g. 3-D printing, laser cutting, waterjet cutting, stamping, pressing, and molding. The materials are, for example, plastic, tin, copper, and other ductile materials.

Another objective of embodiments of the present invention is a construction set that is highly tolerant of manufacturing inaccuracies in both connector and rod components.

A further objective of embodiments of the present invention is a construction set that is flexible as to specific angular orientation. The benefit is that is allows for a large variety of known three dimensional geometries, shapes and two-dimensional tessellations, and for arbitrary sculptural forms and artistic creations.

A still further objective of embodiments of the present invention is a construction set that is easy and satisfying to assemble.

A still further objective of embodiments of the present invention is a construction set that is easy to disassemble and reuse.

A still further objective of embodiments of the present invention is a construction set that is applicable to structures at various scales from small models to large functional structures.

In a one embodiment, a socket in a connector for a construction system includes a receptacle having a top, a bottom and two sides defining a cavity. The cavity has a width and a height where the width is greater than the height. The cavity has a first opening. The first opening and the cavity are formed and configured to receive a rod at the first opening and into the cavity and is further formed and configured to engage with the rod in an interference fit at the top and the bottom of the cavity. This embodiment enables the pieces of the construction set to be assembled with joints that are secure but also enables the pieces to be disassembled easily.

In an alternative embodiment, the socket further includes a second opening on the cavity where the second opening is aligned with the first opening and the second opening is formed and configured to enable at least a portion of the rod to pass through the second opening.

In a further alternative embodiment, the socket includes a beam extending from the receptacle adjacent to the second opening. The beam connects the receptacle to the connector.

In a still further alternative embodiment, the socket has the cavity that is tapered, the cavity cross-sectional area decreasing from the first opening to the second opening. In another alternative embodiment of the socket, the first opening, the cavity, and the second opening are formed and configured to receive a tapered rod. In an alternative arrangement, the receptacle includes a narrow section included in the cavity at the second opening.

In another embodiment, the first opening and second opening of the socket are rectangular. In an alternative arrangement, the first opening and the second opening are oval in shape.

In another embodiment, the receptacle is made of a ductile material. In an alternative arrangement, the receptacle is made of an elastic material.

In another embodiment, a connector in a construction system includes a plurality of receptacles, connected around a central axial point. Each receptacle has a top, a bottom and two sides defining a cavity, the cavity having a width and a height where the width is greater than the height. The cavity has a first opening. The first opening and the cavity are formed and configured to receive a rod at the first opening and into the cavity and to engage with the rod in an interference fit at the top and the bottom of the cavity.

In an alternative embodiment of the connector, each receptacle further includes a second opening on the cavity, the second opening aligned with the first opening, the second opening formed and configured to enable at least a portion of the rod to pass through the second opening.

In a further alternative embodiment of the connector. the receptacles are symmetrically located around the central axial point.

In a still further alternative embodiment of the connector, the connector has at least three receptacles. In an alternative arrangement, the connector has six receptacles. In a still further alternative arrangement, the connector is made of a ductile material. In a still further alternative arrangement, the connector is made of an elastic material.

In another embodiment, a construction system has a plurality of rods and a plurality of connectors. Each connector has a plurality of receptacles, connected around a central axial point. Each receptacle has a cavity, a first opening on the cavity, and a second opening on the cavity. The second opening is aligned with the first opening. Each receptacle further has a beam extending from the receptacle adjacent to the second opening. The first opening, the cavity and the second opening are formed and configured to receive a rod from the plurality of rods at the first opening, for the rod to pass through the cavity and for at least a portion of the rod to pass through the second opening. The first opening and the cavity are further configured to engage with the rod in an interference fit.

In an alternative embodiment of the construction system, each connector in the plurality of connectors has three receptacles.

In a further alternative embodiment of the construction system, the plurality of connectors includes at least one connector having three receptacles where at least one connector has four receptacles, at least one connector has five receptacles, and at least one connector has six receptacles.

In a further alternative embodiment of the construction system, the rods in the plurality of rods have a first end and a second end and are tapered at the first end and the second end. In an alternative arrangement, the rods in the plurality of rods are of varying length.

The present invention together with the above and other advantages may best be understood from the following detailed description of the embodiments of the invention illustrated in the drawings, wherein:

DESCRIPTION

A construction system enables the construction of a variety of assemblages and structures. The construction system includes deformable N-way connectors (where N is typically a number between 2 and 6) and elongated rigid rods. The connectors in some embodiments each include at least one tapered socket configured to receive an end of a rod. The rods are generally cylindrical in shape and are tapered at either end. In some embodiments, the rods are pointed at the ends. The sockets and rods are configured such that each socket and the inserted rod have a limited surface area of engagement for easy assembly and disassembly. Additional aspects of the socket enabling ease of assembly, flexible construction and ease of disassembly will be described below.

FIG.1is a perspective view of a connector100according to one embodiment.FIG.2is a front view of the connector ofFIG.1.FIG.3is a left side view of the connector ofFIG.1.FIG.4is a right side view of the connector ofFIG.1.FIG.5is a top view of the connector ofFIG.1.FIG.6is a bottom view of the connector ofFIG.1.

The connector100includes three beams110arranged around a central point, or central axis105. The beams are also referred to as “arms.” Each beam110has an axial end120and a distal end. The beams110are connected together at the axial ends120. Each beam110has a socket130at the distal end. Each socket130has a first opening155and a second opening160. In the present arrangement, the first opening155and second opening160are elongated and rectangular in shape. For the purpose of clarity of explanation, the long edges of the rectangle are also referred to as the top131and the bottom132and the short edges are also referred to as the sides133. Each socket130is configured to receive and engage with a rigid rod in order to form a construction joint. The socket and the rod will be described in greater detail below.

FIG.7shows the connector100in a first deformed state andFIG.8shows the connector in a second deformed state with the original undeformed states in dotted line. In some embodiments, the connector100is made from an elastic material and in other embodiments the connector is made from a ductile material. For example, the connectors may be made from plastic such as polypropylene, nylon or polyethylene or some copolymer. The connectors may also be made from metal such as copper, tin, aluminum, steel or some other alloy. The present invention should not be considered limited to the list of materials presented here. Process of manufacture for elements of the construction set include 3-D printing, molding, casting, pressing, cutting and bonding. The beams110of the connector100may be flexed, or bent, to suit the structure being constructed.

FIG.9is a perspective view of a horizontal cross-section of the connector ofFIG.1.FIG.10is a perspective view of a vertical cross-section of the connector ofFIG.1.FIG.11is a perspective view of the connector ofFIG.1further including a rod200inserted into one of the sockets to form a construction joint. The details of the sockets130can be seen in the cross-sections inFIG.9andFIG.10. Each socket130is a receptacle135having a cavity150. Each socket130further has a first opening155and a second opening160onto the cavity150. The first and second openings155,160are elongated. In the present embodiment, the first opening155is larger in area than the second opening160. In the present embodiment, the cavity150is tapered toward the second opening160. The cavity150at the second opening160has a narrow section165, the narrow section165having a width similar to the second opening160. Each first opening155is aligned with its respective second opening160such that the socket130can receive a rigid rod200at the first opening155, for the rod to enter the cavity150and then for a portion of the rod to pass through the second opening160and protrude as shown inFIG.10. The socket cavity150is preferably tapered to guide the inserted rod200towards the center of the connector100.

The rod200is substantially rigid and cylindrical in shape. The rod200is tapered at both ends205. In some embodiments, the ends205of the rod200come to a point. The rod200is made from a material such as plastic, wood, metal, bamboo or some other rigid material.

FIG.12shows a cross-section of the socket130close to the first opening155of the cavity150. The socket130seen inFIG.12is undeformed.FIG.13shows a cross-section of the socket130at the first opening155of the cavity150and an inserted rod200. The socket inFIG.13shows some deformation related to forming a joint with the rod200as described below.

The height (shorter dimension) of the first opening155is designed such that the dimension is less than the diameter of the rod cylinder away from the tapered ends205. This ensures that the rod200after insertion into the first opening155and the cavity150engages with the top131and the bottom132of the cavity150. Accordingly, this further ensures that the rod200does not freely move in and out of the socket cavity150axially or rotate within the socket cavity150and that the tapered end205of the rod200contacts the upper and lower inner surface of the socket cavity creating an interference fit having the desired manual insertion resistance and frictional grip between the rod200and connector100.

As described above with regard toFIG.9,FIG.10andFIG.11, the socket cavity150is tapered toward the second opening160of the socket130to guide the rod200towards the center of the connector100as the rod200is inserted. The first opening155is formed and configured to receive the rod200into the cavity150and to engage with the rod200in an interference fit. The narrow portion165of the cavity150and the second opening160are formed and configured for a portion of the rod200to pass through and to protrude beyond the second opening160. That is, a joint between the socket130and the rod200can be made by manually inserting a tapered end205of the rod200into the first opening155of the socket cavity150in a direction parallel to the axis of the beam110and toward the center of the connector100. By pressing the rod200into the socket130in this way an interference fit is created. The socket130is configured to provide an interference fit between the top and bottom inner walls of the socket cavity150and the inserted rod200as shown inFIG.10andFIG.13. This interference fit provides a secure connection between the rod200and connector beam110that enables the user to deform the connector beam110to a desired angular orientation by manipulating the distal end of the inserted rod. Once the desired orientation of the connector beam is achieved, the frictional grip provided by the interference fit maintains the desired orientation within, for example, a larger meshed structure.

In the present embodiment, the rod200is gripped by the upper and lower surface of the first opening155of the socket cavity150against the tapered portion of an end of the rod200. This feature allows for variances in rod diameter, cross sectional shape, taper angle and length thereby reducing the cost of the rod components since tight manufacturing tolerances are not critical to the function of the rod and connector.

The joint between the socket130and rod200can be disassembled by manually pulling the rod200out of the socket130in the opposite direction to that used for insertion. Both the rod200and the connector100can be repeatedly reused.

In the present embodiment, the cross section of the socket cavity first openings155are approximately rectangular. In alternative embodiments, these openings155can by one of many other elongated shapes, for example, an ellipse, an oval, a trapezoid, or an elongated hexagon.

The socket configuration has the following benefits:1. The socket facilitates manual insertion of a rod into the socket by creating a large target for the tapered end of the rod (similar to inserting a thread through the eye of a common needle).2. The socket allows for angular variation between the rod central axis and the central axis of the socket thereby facilitating the creation of angled joint geometries.3. The socket provides an intentionally progressive resistive force to the insertion of the rod so that it can be performed manually by the operator effectively. That is, the rods do not intentionally “snap” into place but can be inserted progressively until the desired location is attained.4. The socket provides an intentionally progressive frictional gripping force between the connector and the rod through elastic deformation of the upper and/or lower socket walls as the rod is inserted and the tapered end is in contact with the upper and lower inner surfaces of the socket cavity.5. The socket allows for variation in the length, diameter, cross-sectional shape, and taper angle of the rod components and still operate as intended as a joint.

FIG.14is a perspective view of an alternative embodiment of the connector. The alternative embodiment is a connector300having two sockets305like the socket described above with regard toFIGS.1-13connected by a single beam.

FIG.15is a perspective view of a second alternative embodiment. The connector shown here has four sockets attached together by four centrally attached beams.

FIG.16is a perspective view of a third alternative embodiment. The connector shown here has five sockets attached together by five centrally attached beams.

FIG.17is a perspective view of a fourth alternative embodiment. The connector shown here has six sockets attached together by six centrally attached beams.

FIG.18is an example structure constructed with connectors and rods that are embodiments of the present invention. The example structure is a model of a tetrahedron, the simplest Platonic solid, made from four (4) connectors according to the embodiment ofFIG.1(also referred to as “three-way connectors”) and six (6) rods. For each corner of the tetrahedron, deformation of the connectors around the central hub is shown. Additionally, for each corner the three rod axes can be seen to converge around a common point in space.

The connectors described herein can be oriented at arbitrary and unequal angles. For example, the beams of the three-way connector arms are, in some embodiments, equally spaced at 120 degrees relative to each other in the undeformed state but can be deformed to create unequal spacing as needed for the desired geometry. The arms can be deformed up and down relative to the plane of the undeformed connector. After inserting the rod into a socket, the rod can be held by the user and used as a lever to manipulate and deform (bend) the connector arm to the desired angular orientation.

Deformation of the connector arm generally occurs at the central hub of the connector—the convergence point of the arms (3). This leads to a joint geometry where all rod axes typically cross at a common point in space regardless of the angular orientation of each rod, thereby maintaining the geometric accuracy of the joint.

A construction system for building 2 or 3-dimensional permanent or temporary meshed assemblages and structures includes multiple deformable N-way connectors (where N is 2, 3, 4, 5, 6 or more) and multiple elongated rigid cylindrical rods with pointed tapers at each end. A collection of many embodiments of connectors and along with many rods (e.g. 10 s to 100 s of each) can be combined to form a construction kit for academic, engineering, educational, recreational and artistic purposes. As described above, the connectors include a plurality of beams, also referred to as “arms” typically in a planar, equally-spaced star-shaped configuration with each arm converging at a central point. At the distal end of each arm is attached a socket with an opening and a shaped cavity for accepting a rod. The rod in a preferred embodiment is tapered at each end.

Each arm of a connector can be manually deformed, that is, “bent”, to create many variable joint geometries. A mesh structure can be constructed by joining rods to each of the sockets of an N-way connector, then joining further N-way connectors to the free unconnected ends of each of the rods, and repeating this until the desired mesh geometry is achieved. Once a rod is inserted in a socket the rod can be used as an extended lever to facilitate the bending and correct orientation of the connector arm connected to the socket. This is a useful method of constructing mesh structures.

The connector arms can be bent in the original undeformed plane to create, for example, planar star-shaped configurations with unequally spaced arms to create planar tessellated structures. The connector arms can also be bent perpendicular to the original undeformed plane to create 3-dimensional joints for creating 3-dimensional structures such as regular and irregular polyhedra, engineering structures, models of molecules such as Carbon nanostructures, and freeform artistic sculptures. In an alternative embodiment of the construction set, the rods can be of varying lengths thereby able to form more fanciful regular and irregular structures.

A benefit of the design of the connector sockets, the double-ended rods with tapered pointed ends, and of the interaction between the sockets and inserted rods is that a large amount of variation in size and shape of both rods and sockets can be tolerated without affecting the correct operation of the construction system. Therefore, both the connectors and rods can be manufactured at a lower cost relative to conventional connector and rod construction systems that require accurate parts and high tolerance manufacture for correct operation.

It is to be understood that the above-identified embodiments are simply illustrative of the principles of the invention. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.