# Patent

## Title
Toy couplers including a plurality of block retaining channels

## Abstract

Building sets including a plurality of blocks and a plurality of clips configured to engage a thickness of one or more of the blocks. Each clip includes a base and first and second substantially parallel extensions extending from the base and defining a channel therebetween into which a thickness of a block is receivable. The width of the channel is substantially equal to the thickness of the block receivable within the channel so that the thickness is frictionally retained therein. In one embodiment, the clip includes a plurality of channels.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 14/962,937 (now U.S. Pat. No. 9,399,177), which is a continuation-in-part of U.S. Design patent application Ser. No. 29/513,902, filed Jan. 6, 2015 (now U.S. Pat. No. D757,860), which is a continuation-in-part of U.S. patent application Ser. No. 13/612,383, filed Sep. 12, 2012 (now U.S. Pat. No. 8,968,046), which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/546,912 filed Oct. 13, 2011, entitled BUILDING SETS INCLUDING BLOCKS AND MAGNETIC COUPLING CLIPS, and U.S. Provisional Patent Application Ser. No. 61/594,850 filed Feb. 3, 2012, entitled TOY COUPLERS INCLUDING A PLURALITY OF BLOCK RETAINING CHANNELS. U.S. patent application Ser. No. 14/962,937 is also a continuation-in-part of PCT Patent Application PCT/US2015/039226, filed Jul. 6, 2015, which claims the benefit of U.S. Provisional Patent Application 62/115,458, filed Feb. 12, 2015. Each of the foregoing patents and applications is herein incorporated by reference in its entirety.


BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to toy building sets, particularly building sets including a plurality of blocks to be indirectly magnetically and/or frictionally coupled together.
2. The Relevant Technology
Various building sets have been used by children and others for decades for amusement and learning. Sets of blocks include a plurality of variously configured blocks that allow a user to stack the blocks on top of one another in order to form various structures or buildings. Stacking configurations that can be achieved are often limited as a result of gravity.
Other building sets have provided magnets sealed within blocks (e.g., U.S. Publication No. 2010/0242250), and multi-shaped non-metallic bodies employing disc shaped magnets so that two adjacent bodies may be magnetically connected together (e.g., U.S. Pat. Nos. 6,749,480 and 5,746,638). U.S. Pat. No. 7,413,493 describes toy magnetic building blocks including a block, a casing affixed to the block, and a magnet within the casing. The magnet allows connections to be made with other similar blocks. One embodiment may also include connectors with a collar to mechanically augment magnetic coupling of the blocks, in which narrowed ends of each block are received within opposite halves of the collar.
Such building systems are severely limited in their ability to build relatively realistic building structures such as those employing post and beam construction in which elongate blocks can be secured to one another in an erector like configuration, but in which connections can be more easily achieved (e.g., by a child between about 4 to about 8). As such, even with existing magnetic building systems, there remain difficulties to be overcome.



BRIEF DESCRIPTION OF THE DRAWINGS
To further clarify the above a more particular description of the disclosure will be rendered by reference to specific examples that are illustrated in the appended drawings. It is appreciated that these drawings depict only typical examples and are therefore not to be considered limiting. The examples will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates an exemplary building set including a plurality of blocks and a plurality of magnetic coupling clips configured to frictionally engage a thickness of one or more of the blocks;
FIG. 2A includes various views of an exemplary magnetic clip including a magnet within the clip base and a channel configured to frictionally engage a thickness of a block;
FIG. 2B includes various views of another exemplary magnetic clip;
FIGS. 2C-2D include perspective and cross-sectional views through clips similar to those of FIGS. 2A-2B;
FIGS. 3A-3C are perspective views of various magnetic clips including two channels, each for engaging a thickness of a block;
FIGS. 3D-3E are perspective views of clips similar to those shown in FIG. 1 but each including an inclined floor surface;
FIG. 3F is a perspective view of a clip including a plurality of channels arranged about a central body or sleeve in a “star” type configuration;
FIGS. 3G-3I are perspective views of clips configured to receive an end of a cylindrical block, as well as a rectangular or square cross-section block;
FIGS. 3J-3O are perspective views of various clips including a central sleeve for slidable reception of a block and further including a plurality of channels arranged about the central sleeve for receiving and retaining a thickness of additional blocks;
FIGS. 3P-3R are perspective views of various clips including two channels, each for engaging a thickness of a block, where an angle between the channels is adjustable (FIGS. 3P-3Q) or fixed (FIG. 3R);
FIGS. 3S-3T are perspective views of additional various clips including multiple channels and/or sleeves for engaging blocks to form a truss-like structure;
FIGS. 4A-4C are perspective views of cylindrical, square, and specialized decorative block configurations, respectively;
FIG. 4D is a perspective view of a block configured as a sheet (e.g., for a wall or roof);
FIG. 4E is a perspective view of a sheet type block including windows;
FIG. 4F is a perspective view of a stair type block;
FIG. 4G is a perspective view of a ramp type block;
FIGS. 5A-5D are perspective views of a square, a triangular, a polygonal, and a circular magnetic intermediate structure for use in providing a desired orientation between respective adjacent clips with the intermediate structure therebetween (e.g., such as clips shown in FIG. 1 or any of the other figures);
FIG. 6A is an isometric view of an alternative clip configuration including multiple channels;
FIG. 6B is a cross-sectional view through the clip of FIG. 6A;
FIG. 6C is a close up plan view of a channel of the clip of FIG. 6A;
FIG. 7 shows a close up perspective view of a clip similar to that shown in FIG. 6A;
FIG. 8 shows a perspective view of the clip of FIG. 7, showing a block retained within a channel of the clip, with the block fully seated within the channel:
FIG. 9 shows a perspective view similar to that of FIG. 8, showing a block retained within a channel of the clip, with the block partially inserted within the channel;
FIG. 10 shows a perspective view similar to that of FIG. 8, showing a block retained within a channel of the clip, with the block inserted at an angle within the channel; and
FIG. 11 shows a perspective view similar to that of FIG. 8, showing two blocks retained within a channel of the clip.



Together with the following description, the figures demonstrate non-limiting features of exemplary devices and methods. The same reference numerals in different drawings represent similar, though not necessarily identical, elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to building sets including a plurality of blocks and a plurality of clips configured to frictionally engage one or more of the blocks. The clips include a magnet enclosed within the clip, which facilitates coupling of various blocks (e.g., elongate “post” and “beam” type blocks) together (with a clip in between) in various configurations not possible when stacking blocks alone (e.g., arches, bridges, trusses, eaves, girders, posts, beams, and other structures and buildings) as a result of the strength of the magnetic coupling. The system allows connection of non-magnetic bodies (i.e., the blocks) into simulated life-like structures such as those noted above through the use of magnetically coupling clips that frictionally engage the blocks. In addition, because the connection between the block and clip is friction based, a high degree of freedom is available in placement of the clips (e.g., anywhere along a side, end, or face of a block, as the case may be for a given clip).
As shown in FIG. 1, each block 102 of building set 100 may typically include a first face 104a, an opposing second face 104b, a first side 106a, an opposed second side 106b, a first end 108a, and an opposed second end 108b. Block 102 is shown as elongate, (i.e., a plank, post, or beam). In one embodiment, an exemplary elongate block may be about 120 mm long, about 25 mm wide, and about 8 mm thick. In one embodiment, the aspect ratio of length to width may be from about 3 to about 7 (e.g., about 5). In one embodiment, the aspect ratio of length to thickness may be from about 10 to about 20 (e.g., about 15). The thickness engaged by the clip 110 may be between about 5 and about 10 mm. Of course, blocks other than elongate blocks may be included within the plurality of blocks in the building set, although in one embodiment, at least some of the included blocks will be elongate (i.e., of the plank, post, beam variety). Of course, more complex block configurations are possible, including decorative features (e.g., as seen in FIG. 4C), as are blocks including rounded surfaces (e.g., as seen in FIG. 4A) where boundaries between faces, sides, or ends may not be discrete. In any case, such blocks are three dimensional, having thicknesses in x, y, and z dimensions.
The building set 100 further includes a plurality of clips 110 configured to engage a thickness of one or more of the blocks. In one embodiment, the clip might engage a thickness of multiple blocks stacked together. Exemplary clip 110 may include a base 112 including a floor 114 against which a surface of a block may be inserted during frictional engagement, and first and second extensions 116, 118 extending upwardly from base 112. Extensions 116, 118 define a channel 120 therebetween and which may be open at a top end adjacent top ends of extensions 116, 118. Channel 120 may also be open at either end, adjacent lateral ends of extensions 116, 118, and floor 114. Channel 120 advantageously has a width that is substantially equal (and slightly less than) the thickness of the block that is receivable and to be frictionally retained within channel 120. For example, the thickness between faces 104a and 104b of illustrated block 102 may be substantially equal to the width of channel 120, between extensions 116, 118 so that the extensions may frictionally retain block 102 when inserted into channel 120. In another embodiment, a clip may be configured with a width of channel 120 that is substantially equal to the thickness between first and second sides 106a and 106b (i.e., to straddle this wider dimension of rectangular block 102).
In addition, it will be readily apparent that clip 110 may be positioned in a variety of locations along side 106a, 106b, or ends 108a, 108b to straddle the thickness between faces 104a and 104b. In other words, attachment of clip 110 to block 102 is not limited to only a single, or even a small number of locations, but may be slid to an infinite number of positions anywhere along sides 106a, 106b, or ends 108a, 108b. This characteristic provides an increased freedom in building that is not possible with fixed connection systems, in which connection is only possible at a single (or small number of) predetermined location(s).
In addition to the frictional retaining engagement provided by extensions 116 and 118 of clip 110, clip 110 further includes a magnet enclosed therein (e.g., within base 112) so that base 112 of clip 110 may be coupled to the base of another clip when the enclosed magnets are positioned close to one another. Of course, a magnet may be enclosed elsewhere within clip (e.g., within one or more of extensions 116, 118) to provide magnetic coupling between any portion of two clips including encased magnets. This frictional engagement and magnetic engagement configuration allows blocks to be stacked or positioned adjacent to one another, typically with clips disposed in between, providing a much more robust connection between the blocks than is possible with simple stacking.
For example, blocks may be cantilevered much like a house of cards, while clips positioned in between individual blocks provide a much stronger connection throughout the entire structure. For example, it may be possible to lift such a structure off a floor or other supporting surface, while it maintains its structural integrity. In order to provide even better structural integrity, the building structure may include clips frictionally engaged on blocks at the bottom of the structure, adjacent the floor or other supporting surface, while the supporting surface comprises a magnetically attractable pad or building surface to which the clips (and thus the super-structure thereabove) are strongly magnetically coupled.
Also shown in FIG. 1 is another block 102a having a thickness dimension between opposed faces that is the same as block 102, and which could therefore also be engaged within channel 120 of clip 110. Another configuration of a clip 110a similar to clip 110 is also shown in FIG. 1, the principal difference being that bottom 124a of the base of clip 110a is rounded, rather than being substantially flat, as is bottom 124 of base 112 of clip 110. This configuration allows clip 110a to magnetically couple to clip 110 (or another clip 110a) at any desired angle between respective clip channels. In other words, the rounded bottom 124a of clip 110a can be rotated against bottom 124 of clip 110 to a desired angle. Blocks may be frictionally engaged within channels 120 of one or more clips 110, 110a. FIG. 2A shows 6 views of clip 110 (4 elevation views as well as top and bottom views), while FIG. 2B shows the same views of clip 110a. Other rounded or angled configurations to the clip bottom surfaces (or surfaces of extensions) are also possible (e.g., rounding outer surfaces of extensions 116, 118, providing an angled surface to bottom 124, etc.).
As described, each clip includes a magnet 122 encased within base 112 of clip 110, 110a. Besides the difference in the configuration of exterior bottom surface 124, FIGS. 2A-2B also show alternative magnet configurations. Referring to clip 110 of FIG. 2A, magnet 122 may be a generally cylindrical shaped magnet having a relatively short height to the cylinder, and which is oriented with the height axis of the cylinder generally parallel to the extensions 116, 118. Such a shape may resemble a hockey puck. A pocket may be formed within base 112 that is slightly larger than magnet 122 so as to allow magnet 122 to rotate about its height axis. In another embodiment, magnet 122 may be fixed relative to base 122, so that no rotation occurs.
As shown in FIG. 2B another configuration may include a generally cylindrical shaped magnet with a greater height dimension (i.e., greater height to diameter ratio), while the magnet may also be oriented differently, so that the height axis of magnet 122a is generally parallel to a longitudinal axis of the clip (e.g., resembling a rolling pin). In other words, the height axis of magnet 122a may be generally perpendicular to extensions 116, 118. In the illustrated configuration, pocket 126 is oversized relative to magnet 122a, so as to allow magnet 122 to rotate about its height axis, and perhaps even slide somewhat in the height direction of the cylinder. Puck shaped magnet 122 may sometimes commonly be referred to as a disc magnet, while rolling-pin shaped magnet 122a may commonly be referred to as a cylindrical magnet. A disc magnet may have a N and S on opposite surfaces of the disc. An alternative configuration may employ square or rectangular shaped magnets. In one embodiment, cylindrical magnets may be magnetized on the long axis of the cylinder. This may allow the magnet to pivot and rotate. Discs and similar shapes can magnetically couple along their edges. Of course any magnet configuration may be employed with any clip configuration (e.g., a “rolling pin” in an oversized pocket configuration may be used with a clip 110 including a planar exterior surface). FIGS. 2C and 2D show cut away views of the embodiment shown in FIG. 2A. FIG. 2D also shows a cut away view of an embodiment similar to that shown in FIG. 2A but with a “rolling pin” shaped magnet as in FIG. 2B.
Strongly magnetic rare earth neodymium and/or samarium-cobalt magnets are particularly preferred, although other types of magnets (e.g., AlNiCo magnets, ceramic magnets, and/or ferrite magnets) may also be used. Permanent magnets are preferred.
FIGS. 3A-3C show various clip configurations including two channels, although other two-channel configurations are also possible. The embodiment of FIG. 3A resembles two clips positioned with extensions adjacent to one another, and the orientation of the channels oriented 180° relative to one another. The embodiment of FIG. 3B resembles two clips positioned with the bottom surfaces of bases positioned adjacent to one another, with channels are oriented 180° relative to one another. The embodiment of FIG. 3C resembles two clips with the face surfaces of extensions positioned adjacent to one another and with the orientation of the channels aligned, to be parallel to, and next to, one another. Of course, such configurations could be made with two separate clips such as seen in FIG. 2A, or could be molded or otherwise formed (e.g., machined) as an integral piece, as seen in FIGS. 3A-3C. The illustrated clip includes a U or C shaped channel. Other embodiments may include channels or clip bodies that are angled, L shaped, T shaped, include any number (e.g., 3, 5, 7, etc.) radial connections. FIGS. 3A-3C illustrate two channel configurations, although similar configurations including 3 or more channels could also be provided.
FIGS. 3D and 3E show clips similar to the two configurations seen in FIG. 1, but in which the floor 114 of each is inclined towards one end of open channel 120. Such a clip may be magnetically coupled to a clip as shown in FIG. 1 in a configuration similar to that seen in any of FIGS. 3A-3C (e.g., as in FIG. 3B) to provide an angled relationship (e.g., greater than or less than 180°) between a block received within the channels of each clip. For example, the angle of the incline may be greater than 0° and less than 90°, between about 10° and about 80°, or between about 30° and about 60°, e.g., about 45°)
FIG. 3F illustrates a star-like clip configuration resembling 8 clips positioned around a central sleeve or central body. The clip of FIG. 3F includes 8 channels 120, while the central sleeve or body also includes center sleeve or hole 128 which is aligned with a central longitudinal axis of the clip of FIG. 3F. Sleeve 128 may be open at both ends, or closed at a bottom end and open at only one end. Sleeve 128 may be sized to receive both a face-to-face thickness of a block as well as a side-to-side thickness of a block simultaneously. The sleeve or hole may be cylindrical to receive a cylindrical block, it may be rectangular to receive a rectangular block, or it may be as shown, including both rectangular and cylindrical features to be capable of receiving either. Where the bottom of sleeve or hole 128 is closed, a magnet may be disposed at the bottom of this closed bottom.
Although a particular configuration of a star-like clip is shown in FIG. 3F, it will be understood that other similar configurations are also possible. For example, more or less than 8 channels could be included (e.g., 2, 3, 4, 5, 6, 7, 9, 10, etc.). In addition, they may be equally distributed about the central body, so angles therebetween are equal, or they may not be equally distributed, so angles therebetween are not all equal. In another embodiment, no central sleeve or hole may be present, but rather simply a solid body (i.e., as if hole 128 were filled).
FIGS. 3G-3I illustrate clips that are configured to receive both a face-to-face and a side-to-side thickness of a block, which may be rectangular in cross-section or may be cylindrical (i.e., circular in cross-section). Other configurations will also be apparent to one of skill in the art in light of the present disclosure—e.g., a clip with an oval hole for receiving a block having an oval cross-section. Magnets may be disposed within the peripheral edges of body 212 of clip 200. Where clip 200 is closed at the bottom rather than being an open sleeve, a magnet may be disposed within the body adjacent the closed bottom surface.
FIGS. 3J-3O illustrate additional various relatively complex contemplated clip configurations including an optional sleeve or hole 128 (where a bottom of the hole is closed) and one or more channels 120 for retaining a thickness of a block. As shown, the various channels 120 may be arranged in any orientation relative to each other. FIG. 3J shows a clip including two channels 120 on opposite sides of a central sleeve or hole 128, with the axis of the channels 120 parallel to one another and to the sleeve or hole (i.e., all 3 coparallel to one another). For example, in the illustrated orientation all channels and sleeve/hole are configured to receive block members in a substantially vertical orientation.
FIG. 3K shows another example with only a single channel 120, otherwise similar to the configuration of FIG. 3J. FIG. 3L shows an example with 4 channels, similar to that of FIG. 3J, but with additional channels 120 at either side of sleeve or hole 128. FIGS. 3M and 3N show additional variations of such clip configurations. In FIG. 3O, clip channels 119 are shown oriented transverse to clip channels 120, so that if clip channel 120 secures a block in a vertical orientation, clip channels 119 may be used to secure blocks in horizontal orientations. Various additional configurations will be apparent to one of skill in the art in light of the present disclosure.
FIGS. 3P and 3Q show a clip configuration including two channels, and in which the angle between channels 120 may be selectively altered. For example, one may rotate one half of the clip relative to the other half about a hinge structure to select any desired angle (e.g., between about 0 and about 90°, between about 10° and about 80°, or between about 30° and about 60°). Any suitable hinge structure may be employed within such a clip (e.g., a pin hinge, a ball joint, etc.). The clip adjustment mechanisms may remain where positioned (e.g., include a locking feature) so as to prevent the selected angle from changing without the user making the adjustment. FIG. 3R illustrates another configuration including an angle between channels 120, but in which the angle is fixed, rather than adjustable. Any desired angle between 0 and 90° or within those ranges mentioned above may be provided. Such angled channel configurations may be particularly helpful for building the intersection of a wall with a roofline, or when building a truss or bridge structure.
FIGS. 3S-3T show additional clip configurations, which clips include multiple channels and multiple sleeves or holes. The configuration shown in FIG. 3S shows a channel 119 oriented substantially transverse to channels 120. In other words, end channels 120 may be oriented vertically, while channel 119 may be oriented horizontally. Top, center channel 120 is rotated 90° relative to horizontal channel 120 “into the page”. FIG. 3T shows a similar truss like clip configuration, but in which channel 119 is rotated to also be in a vertical orientation as channels 120. Clips or blocks for use in construction of a toy bridge may include a string or cable attached to the block or clip that can be strung between structure to resemble suspension cables. The various clip configurations are shown to describe some of the contemplated configurations. It will be understood that numerous other configurations are also possible, and are intended to be within the scope of the present invention.
In a broad context of one embodiment, the various clip configurations may include a pair of substantially parallel extensions configured to receive and frictionally retain a thickness of a block, while the clip further includes a magnet within a base (and/or even the extensions) of the clip in order to magnetically couple the magnet of the clip to another magnet, or to a magnetically attractable material (e.g., to a metal box top or other magnetically attractable pad that can act as a building base).
In one embodiment, the building set may be packaged within a metallic box, in which the box lid may be used as such a building base to providing magnetic coupling to the magnetic clips.
The clips may be formed of plastic or any other suitable material (e.g., plastic, wood, metal, carbon fiber, etc.). They may be formed by injection molding, machining, or other suitable technique. The magnet(s) within each clip are advantageously encased within the plastic or other material so as to prevent them from falling out or otherwise becoming dislodged. In one embodiment, the clips are not formed of wood to prevent such an issue (although perhaps a wooden clip could include a magnet encased therein in which an access hole used to place the magnet is back filled with glue, composite, epoxy, etc. Various techniques of inserting one or more magnets into a block are disclosed in U.S. Publication No. 2010/0242250, herein incorporated by reference. Such techniques could be adapted for providing a magnet within any clip according to the present invention. In addition, in one embodiment, one or more of the provided blocks may include a magnet encased therein, although in one embodiment, no magnets are provided within the blocks, rather the magnets are frictionally connected to the blocks through use of the clips. In one embodiment, the clips may be formed by bonding two halves about the magnet(s) (e.g., through sonic bonding).
FIGS. 4A-4G illustrate various contemplated block configurations in addition to those shown in FIG. 1. FIG. 4A shows a cylindrical block, FIG. 4B a square cross-sectioned block, and FIG. 4C a specialty decorative block that may have various decorative patterns or shapes formed therein. FIG. 4D shows a block in the form of a relatively large sheet (e.g., with a thickness equal to that of the blocks of FIG. 1 but with significantly greater width dimensions (e.g., 3 times greater, 5 times greater, or 7 times greater). Such a sheet may be used as a wall or roof panel when building, and the thickness of the sheet may be engaged by the clips. FIG. 4E shows a sheet similar to that of FIG. 4D, but which includes windows formed therein. FIG. 4F shows a block in the shape of a set of stairs, while FIG. 4G shows a ramp. Any of such blocks may include a thickness (e.g., either face-to face, side to side, or end to end) that is engagable by a clip included within the building set. An attached photograph in the provisional application shows various additional block configurations. Another attached photograph of the provisional application shows how various plank, post, or beam elongate blocks may be frictionally engaged to clips, which in turn may be magnetically coupled to another clip to achieve various structural erector-like configurations simply not possible with existing magnetic block building sets.
In one embodiment, blocks may include any of various features incorporated therein. For example, the Figures show blocks shaped as stairs, walls, including windows, etc. Other configurations will also be apparent to one of skill in the art in light of the present disclosure. For example, a block may include a pulley incorporated into the block so that a width of the block may be engaged within a given clip, allowing the pulley (or other feature) to be indirectly coupled to the clip.
The blocks may be formed of any suitable material (wood, plastic, metal, carbon fiber, composite material, etc.). In one embodiment, the blocks are formed of wood or a plastic or composite material resembling wood.
FIGS. 5A-5D shows intermediate structures for use in conjunction with the clips that also include a magnet disposed within the intermediate body, and which can be used with the magnetic clips in order to provide a desired orientation between the intermediate structure and two or more adjacent clips. For example, FIG. 5A shows a square or rectangular intermediate in which clips could be positioned (and magnetically coupled) along any of the 4 edges, or even the top or bottom surface of the intermediate structure. FIG. 5B shows a similar intermediate but including a 3-sided triangular configuration. FIG. 5C shows a polygonal intermediate structure including 7 sides, and FIG. 5D shows a circular configuration of an intermediate structure, which would allow clips to be positioned at any desired angle relative to one another (as opposed to a rectangular configuration as in FIG. 5A that is fixed at 90°, or a triangular configuration as in FIG. 5B fixed at 120°, or the configuration of FIG. 5C fixed at 51.4°). In one embodiment, one or more magnets may be disposed within the intermediate body at a location spaced apart from a center of the body, adjacent to a perimeter surface. For example, a rectangular intermediate body may include magnets positioned within the body adjacent to all 6 perimeter surfaces, while a triangular intermediate body may include magnets positioned within the body adjacent to all 3 perimeter surfaces. A circular intermediate body may include magnets location at various points inside of the circular body, relatively close to the perimeter exterior surface. In another embodiment, it may be possible to position a disc shaped or doughnut shaped magnet within the body to be adjacent to the entirety of the outer perimeter surfaces. Such intermediate structures may be formed of similar materials as described for the clips.
Another contemplated embodiment of a building set may include a plurality of elongate rods, or straight sided (e.g., square or rectangular) blocks or sticks that include a rounded bulb-shaped enlarged end (or such enlargements at two or more ends). Each rounded end would house a magnet enclosed within the bulb. The magnet within the enclosing bulb may be pivotable, like a ball joint to allow it to pivot as needed to correctly orient magnetic poles. Attached pictures illustrate the concept with q-tips including rubber cement at their enlarged rounded ends to simulate placement of such magnets. Such building structures could be connected in myriad ways because the enlarged tip (or at least the magnet housed therein) can rotate as much as about 360°. Sticks or rods of varying length could be provided, which can be magnetically coupled to one another. Such elongate rods could be used in conjunction with the previously described embodiments, or separately, without the need for clips to connect adjacent blocks.
FIGS. 6A-6C show various views of an alternative clip configuration 310 that includes multiple channels 320. Clip 310 may not include a magnet within the body, but rather includes multiple channels 320 that allows clip 310 to engage one or more blocks (e.g., such as rectangular block 102 of FIG. 1). Any of the above described clip configurations including multiple channels could similarly be manufactured without a magnet encased within the body.
Clip 310 includes a central body 330 and a plurality of channels 320 disposed so as to extend from central body 330. Although four channels are illustrated, it will be understood that more or fewer channels may be provided (e.g., 2, 3, 5, 6, etc.). While each channel 320 is illustrated as being configured with equal width, it will be understood that one or more of the channels may have a different width than another of the channels. In addition, while all channels are shown to be oriented in a particular orientation, it will be understood that one or more of the channels may be differently oriented (e.g., transverse). For example, FIGS. 3O and 3S illustrate embodiments of clips in which channels are oriented transverse to one another.
Each channel 320 of clip 310 includes a base 312 disposed on central body 330. Each base 312 defines an interior floor surface 314 of each channel 320. The sides of each channel 320 are bounded by extensions 316 and 318, which are substantially parallel to each other. In an embodiment, the interior surfaces of each extension within channel 320 may be formed of planar surfaces, without any protrusions formed thereon, as shown. In other embodiments, one or more protrusions (e.g., apexes) may be formed thereon. Floor surface 314 may be a single planar surface, as shown. As described above, a thickness defined between opposed faces, sides, or ends of one or more blocks is receivable within any of channels 320. The width of channel 320 is substantially equal to the thickness of the corresponding block that is retainably engaged within a given channel.
As will be apparent from the disclosure and drawings, the described configuration allows the block to be rotated within the channel to form a variety of desired angles between the floor of the channel and a side or end of the block inserted into the channel.
As seen in FIGS. 6A-6B, a centrally disposed cylindrical hole 328 may be provided within central body 330. Hole 328 may be open at both ends (e.g., as a tunnel). A cylindrically configured block may be inserted within hole 328. For example, an axle for a wheeled vehicle as shown in the attached photograph with the provisional filing may be inserted through hole 328. Various other accessories (e.g., an anchor for a crane, hooks, pulleys, flags, windmill axles, etc.) may similarly be provided in this way.
Central body 330 and channels 320 may advantageously be configured to provide independence between the plurality of included channels. For example, insertion of a block into one channel does not substantially interfere with the ability of another channel of the clip 310 to retain a block with substantially the same retention force that would be provided if only a single channel had a block received therein. Some similar toy coupler configurations within the prior art suffer from lack of independence between individual coupling mechanisms of the device. For example, when a second block or piece is inserted within a second coupler mechanism, it may cause a first already inserted block or piece to fall out or be retained with a substantially reduced retention force (i.e., so that it may easily fall out if bumped or jarred). The ability to provide independence to each channel is particularly advantageous, as it allows any or all of the channels to be employed without risk that the structure will become unstable as a result of weakened retention force for the frictionally engaging channels.
Independence is provided through a combination of features of the central body, the channels themselves, and the material from which the clip is formed. For example, the clip may be injection molded from a relatively rigid plastic material such as polycarbonate. Rigidity of the material from which the clip is formed aids in providing the desired independence. Furthermore, the central body 330 may include a plurality of stabilizing ribs 332 extending outwardly from the cylindrical wall bounding central hole 328 towards a portion 334 of extensions 316 and 318 that extend beyond base 312. The clip may include ribs that are substantially equally spaced between channels 320, so that the clip includes an equal number of ribs 332 and channels 320. Ribs 332 aid in preventing stresses and forces applied to extensions 316 and 318 from being transferred from one channel to the extensions of another channel of clip 310 when a block is retained within a given channel 320.
Central body 330 may further include a plurality of flanges 336 centrally disposed between base 312 of channel 320, portions 334 of extensions 316 and 318, ribs 332, and the cylindrical wall of hole 328. The flange 336 may fill the area of space shown in FIG. 6C between these structures, without filling the entire depth of the clip, as reflected in FIGS. 6A and 6B. For example, flange 336 may have a thickness approximately equal to that of extensions 316, 318, base 312, cylindrical wall defining hole 328, or ribs 332 (e.g., as shown in FIG. 6B)
FIG. 6C shows a close up plan view of one of channels 320 extending from body 330, perhaps best showing the details of extensions 316 and 318. As shown in FIG. 6C, at least a portion of the interior surface of each extension 316, 318 defines an angle relative to floor 314 that is less than 90° so that extensions “pinch” the thickness of a block received within a given channel 320, frictionally coupling the clip 310 to a block received within extensions 316, 318 of a respective channel 320. As shown in FIG. 6C, the interior surface of each extension 316, 318 may include four distinct portions. A first portion 338 is disposed adjacent to floor 314, and is formed perpendicular (i.e., 90°) relative to floor 314. A second portion 340 between the first portion 338 and a third portion 342 provides an angle relative to floor 314 that is less than 90°. For example, the angle between portion 340 and floor 314 may be from about 85° to less than 90°, or from 86° to 88° (e.g., 87°). A third portion 342 between second portion 340 and a fourth distal portion 344 may be formed so as to be perpendicular relative to floor 314. Fourth distal portion 344 may be formed to be outwardly flared so as to provide an angle relative to floor 314 that is more than 90°. For example, the angle between portion 344 and floor 314 may be from 92° and 98° (e.g., 95°).
Depending on the tolerances achieved during manufacture, the four distinct differently angled surfaces may be somewhat muddled as a result of shrinkage of the plastic or other material during manufacture or other reasons. For example, a finished manufactured product may be readily observed to include at least two portions. For example, a proximal portion (e.g., corresponding to portions 338 and 340) may overall provide an angle relative to the floor that is less than 90°, while a more distal portion (e.g., corresponding to portion 342 and perhaps 344) provides an angle relative to floor 314 that is at least 90°. Such is visible in FIG. 7, where an apex 321 is formed at the intersection of the proximal and distal portions, which apex protrudes into channel 320.
The width of channel 320 may thus vary somewhat according to location within the channel 320. For example, the width of channel 320 adjacent floor 314 may measure somewhat larger than the thickness of a block to be engaged within channel 320. Channel width may progressively narrower through the portion of channel 320 corresponding to portion 340 (as portions 340 on each side of channel 320 are “pinch” angled). The width of channel 320 corresponding to distal portion 344 may quickly be somewhat larger (as a result of its outward flare) than the thickness of the block (e.g., similar to portion 338). As a result, substantially all of the frictionally engaging retention force for retaining a block within channel 320 may be provided along portion 342.
In one embodiment, portion 342 may account for about 35% to about 45% (e.g., about 40%) of the depth of channel 320. In one embodiment, the channel may have a length that is substantially equal to a dimension of a corresponding dimension of one or more of the blocks (e.g., about 23 mm). Width of channel 320 along corresponding to portions 338 may measure 0.310 inch, while the width at the opening of channel corresponding to portions 344 may measure 0.294 inch. For example, the width may narrow by about 1% to about 10% over the channel width (e.g., about 5%).
In addition to providing independence between the various channels of the clip 310, the retaining force provided by each channel and a given block is preferably relatively strong, so as to prevent a block from falling out of a channel inadvertently. Of course, the retaining force provided requires that the dimension of the block to be retained be sized for use with the friction retaining channel. Where the dimensions are approximately equal, so that the block is frictionally retained within channel 320, the features described above (e.g., pinching configuration of the interior surfaces of channel 320, structural ribs 332 and flanges 336, selection of a rigid plastic such as polycarbonate) provide a retaining force so that from about 1 lb to about 5 lbs of pull out force is required to pull a block that engages substantially all of the length of the channel out of the channel.
In other words, where the block is sized smaller than the channel length, or only half or a portion of the block dimension is engaged within the channel, (so that a plurality of blocks may be received within the same respective channel at the same time), or the block is only partially inserted into the channel while still being retained therein, which capabilities will be apparent from the drawings, the actual retention force will be less for that particular configuration, although the retaining force available when the channel length is fully engaged will be 1 lb to about 5 lbs. In another embodiment, the provided retaining force is from about 2 lbs to about 4 lbs of pull out force to pull the block out of the channel.
In testing the pull out force, 6 blocks of approximately equal size and shape (as shown in the photograph of the wheeled vehicle in the provisional application) were fully inserted within the illustrated clips and were pulled out. A fish scale was used to measure the weight or force required to achieve pull out. The results as shown in Table I below.











TABLE 1






First Try
Second Try
Third Try
Average


Block
(lbs)
(lbs)
(lbs)
(lbs)



















1
3.5
3.2
3.0
3.2


2
3.1
3.3
3.2
3.2


3
4.0
3.5
4.0
3.8


4
2
2
2
2


5
3.5
3.5
3.2
3.4


6
2.5
2.7
2.5
2.6









It was observed that although the blocks were all approximately equally sized 8 mm×23 mm×118 mm, minor variances within the block dimension engaging the channel (i.e., 8 mm) have an effect on the retention force. For example, block 4 was observed to be somewhat thinner than the nominal 8 mm dimension, resulting in its lower retention values. Still, the retention value of 2 lbs will typically be sufficient for contemplated use. The particular configuration described in conjunction with FIGS. 6A-6C provides a retention force with the contemplated blocks that allows for self-supporting, large structures while allowing a young child (e.g., even a 3 or 5 year old) to connect them together without difficulty. Furthermore, independent retention of the blocks so that one engaged block does not substantially affect the retention force of the other engaged blocks is particularly beneficial.
FIGS. 8-11 illustrate a few ways in which the clip 310 may be used to retain one or more blocks within any of the channels 320. As seen, the connection mechanism is open-ended, rather than binary in nature, so that the block 102 may be coupled in a nearly infinite number of ways and orientations, allowing the builder much more flexibility in building than available with many existing connection mechanisms. For example, a block 102 may be fully seated within the channel 102 (FIG. 8), it may only be partially inserted (FIG. 9), it may be slid within the channel, so that part of the block is slid out of the channel (FIG. 11), it may be rotated to an angle, relative to the channel (FIG. 10), and multiple blocks may be inserted and retained within the same channel (FIG. 11). It will be apparent that only partial insertion of the thickness of the block 102 into the channel 320 towards the base defining an interior floor surface of the channel is typically needed to retain the block in the channel (see FIGS. 9-10), and that a plurality of blocks may be received within the same respective channel at the same time (FIG. 11 and even FIG. 10—which includes unoccupied channel space that could accept another block 102). The block 102 can be rotated within the channel 320 to form a variety of desired angles between the floor of the channel 320 and a side or end of the block inserted into the channel (FIG. 10). For example, in FIG. 10, block 102 retained in channel 320 is retained in the channel with the block being inclined relative to the floor of the channel, and is such that it may be rotated, to allow the user to select any one of various incline angles relative to the floor of the channel.
Photographic FIGS. 31-40 included in the priority provisional application (Ser. No. 62/115,458) show additional features of the open-ended nature of the connection mechanism between the channel of the connector clip and one or more blocks. FIG. 35 shows as many as 4 blocks retained within a single channel (2 on each side). Further description of this open-ended nature is found in the prosecution history of U.S. Pat. No. 8,968,046, also herein incorporated by reference.
Such connectivity between a block 102 and a channel 320 is not binary—either “snapped” into a corresponding receptacle or not. Because the system is not binary, this allows the building set to provide unique and different building characteristics such as partial or full engagement, ability to rotate the block to any angle relative to the floor of the connection channel, the ability to connect the block into the channel at any location along the length or ends of the block (i.e., “connect anywhere”), the ability to place multiple clips onto a length of the block, and the ability to retain multiple blocks into a single channel, etc.
It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

## Claims

1. A building set, comprising:
a plurality of blocks, each of the blocks having at least two faces substantially parallel to each other with a thickness defined therebetween;
a plurality of rigid plastic clips configured to engage the thickness of one or more of the plurality of blocks, each clip including a plurality of block engaging channels, each channel of the clip including:
a base defining a floor;
first and second substantially parallel extensions, each including interior surfaces, the extensions extending distally from the base and defining a channel therebetween into which the thickness of the blocks is receivable in a manner that the blocks can be retained by the faces being frictionally engaged between the first and second extensions, where only partial insertion of the block into the channel towards the base defining an interior floor surface of the channel is needed to retain the block in the channel.

2. The building set of claim 1, wherein at least a portion of the interior surface of each of the first and second extensions of each channel define an angle relative to the floor of the base of each channel that is less than 90° so that the extensions pinch the block received within one of the channels, frictionally coupling the clip to a block received between the extensions of a respective channel.

3. The building set of claim 2, wherein the channel and the block provide a retaining force so that from about 1 lb to about 5 lbs of pull out force is required to pull the block out of the channel.

4. The building set of claim 2, wherein the interior surface of each extension includes:
a proximal portion adjacent to the floor that provides an angle relative to the floor that is less than 90°; and
a distal portion adjacent to the proximal portion that provides an angle relative to the floor that is at least 90°.

5. The building set of claim 1, wherein a width of the channel is narrowed along a portion thereof, the narrowing being from 1% to 10%.

6. The building set of claim 1, wherein the rigid clip includes a centrally disposed cylindrical tunnel.

7. The building set of claim 1, wherein the interior surface of each extension includes:
a first portion adjacent to the floor that is perpendicular to the floor;
a second portion adjacent the first portion that provides an angle relative to the floor that is less than 90°; and
a third portion adjacent the second portion that provides an angle relative to the floor that is perpendicular to the floor; and
a fourth portion adjacent to the third portion that is outwardly flared to provide an angle relative to the floor that is more than 90°.

8. The building set of claim 1, wherein the interior surface of each extension includes a plurality of portions at different angles relative to the floor, so as to define one or more apexes along a given extension.

9. The building set of claim 1, wherein the one or more apexes protrude into the channel.

10. The building set of claim 1, wherein the interior surfaces of each extension are planar.

11. The building set of claim 1, wherein the interior surfaces of each extension are devoid of protrusions.

12. A building set, comprising:
a plurality of blocks, each of the blocks having at least two faces substantially parallel to each other with a thickness defined therebetween;
a plurality of rigid clips configured to engage the thickness of one or more of the plurality of blocks at any location of said thickness, each clip including one or more block engaging channels at a periphery of the rigid clip, each channel of the clip including:
a base defining a floor;
first and second substantially parallel extensions, each including interior surfaces within the channel, the extensions extending distally from the base and defining the channel therebetween into which the thickness of at least one of the plurality of blocks is receivable in a manner that the block is retained by the faces being frictionally engaged between the first and second extensions, the channel being configured such that a plurality of blocks may be received within the same channel at the same time.

13. The building set of claim 12, wherein the block is retained within the channel whether the block is fully inserted into the channel or only partially inserted into the channel, so that only partial insertion of the thickness of the block into the channel towards the base defining an interior floor surface of the channel is needed to retain the block in the channel.

14. The building set of claim 13, wherein the channel and block are configured to allow a block retained in the channel of the clip to be retained in the channel at a selected one of various angles relative to the channel.

15. The building set of claim 13, wherein the channel and block are configured to allow a block retained in the channel of the clip to be retained in the channel with the block being inclined relative to the floor of the channel at a selected one of various incline angles relative to the floor of the channel.

16. The building set of claim 13, wherein the interior surfaces of each extension are devoid of protrusions formed thereon.

17. The building set of claim 13, wherein at least a portion of the interior surface of each of the first and second extensions of each channel define an angle relative to the floor of the base of each channel that is less than 90° so that the extensions pinch the faces of the block received within one of the channels, frictionally coupling the clip to a block received within the extensions of a respective channel.

18. The building set of claim 13, wherein the interior surface of each extension includes:
a proximal portion adjacent to the floor that provides an angle relative to the floor that is less than 90°; and
a distal portion adjacent to the proximal portion that provides an angle relative to the floor that is at least 90°.

19. The building set of claim 13, wherein a width of the channel is narrowed along a portion thereof, the narrowing being from 1% to 10%.

20. The building set of claim 12, wherein the blocks are rectangular.

21. The building set of claim 1, wherein the blocks are rectangular.