Abstract:
A modular toy construction system employing frictional channel connections, which supports combining an assortment of simple modular components without special tools. The system includes a series of post, panels and foundation pieces. Channels are pre-cut to allow the panels to slide into place, or for connectors to seat in the channels of adjacent pieces forming a clean joint between two channeled parts. Assembly in this fashion provides a friction fit and achieves substantial stability. This stability is present in completed and partially assembled structures, allowing whole projects or sections thereof to be moved during construction with minimal risk of structural collapse. The system supports the possibilities of a wide variety of configurations and specialty pieces, which may be added to effect distinct characteristics, features and looks.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to toy construction systems, and particularly to erection systems having a plurality of elements, which may be put together in a variety of ways to form various structures. 
     2. Desciption of the Related Art 
     Toy construction systems with posts and panels, designed in a modular nature are known to the prior art. The following patents illustrate such systems: 
     U.S. Pat. No. 797,640 discloses a toy house having channeled posts, panels to slide into the channels and transverse post notches for interconnecting posts. 
     U.S. Pat. No. 1,492,560 discloses building blocks including posts with channels on all four sides, panels to slide into the channels, transverse post notches for interconnecting posts and dowels extending from some post ends. The dowels engage round holes provided in panels and other posts, but not the post channels. 
     U.S. Pat. No. 1,828,309 discloses a structural building unit having tension connectors to position and hold components together. 
     U.S. Pat. No. 3,571,965 discloses a construction unit having channeled posts, rectangular structural pegs at the end of at least some posts, and holes in the post channels from which round pegs can protrude in order to support panels engaged in the channels. 
     U.S. Pat. No. 4,270,302 discloses an erection set including a solid base with positioning apertures, panels and channeled posts such that the post shape ends securely fit in base apertures. 
     U.S. Pat. No. 4,334,868 discloses a construction kit with channeled posts and panels that press into the channels, where posts can only connect to panels, and vice versa. Panels are securely fixed in the posts by friction. 
     U.S. Pat. No. 5,036,634 discloses a structure including channeled posts, panels to slide into the channels and transverse post notches for interconnecting posts. 
     U.S. Pat. No. 5,779,517 discloses a construction kit with a one-piece structural base, posts with channels, panels to slide into the channels, and dowels extending from the vertical post ends to position posts on base unit. 
     U.S. Pat. No. 6,073,404 discloses a modular building using tension hooks and threaded connectors for maintaining base to base and base to wall component continuity. 
     In order to access the benefits of creative play, toy construction systems have attempted to incorporate certain characteristics and features, such as simply configured interlocking construction components, variable assembly options, and structural stability during and after construction. To obtain these features, sets have employed various techniques. 
     Frequently, to provide structural stability, many systems employed some type of single-piece base component taught in U.S. Pat. No. 797,640 issued to Thompson on Aug. 22, 1905, U.S. Pat. No. 3,571,965 issued to Gibb on Mar. 23, 1971, U.S. Pat. No. 4,270,302 issued to Dandia on Jun. 2, 1981, and U.S. Pat. No. 5,779,517 issued to Clarke on Jul. 14, 1998, or an interlocking foundation component as taught in U.S. Pat. No. 1,492,560 issued to Fisher on May 6, 1924, U.S. Pat. No. 5,036,634 issued to Lessard et al. on Aug. 6, 1991, or U.S. Pat. No. 6,073,404 issued to Norfleet on Jun. 13, 2000. The single-piece base systems have limited flexibility in their design and a single-piece base restricts the compactness of the disassembled construction set. The interlocking systems either employ intricate hooking or threaded devices more difficult for younger, less skilled users, or larger, less flexible hands to manipulate, or they use a notched transverse post configuration producing a more bulky, unsightly union. 
     Many construction sets use channeled posts with panels that slideably engage the posts to create wall structures as taught by U.S. Pat. No. 797,640 issued to Thompson on Aug. 22, 1905, U.S. Pat. No. 1,492,560 issued to Fisher on May 6, 1924, U.S. Pat. No. 3,571,965 issued to Gibb on Mar. 23, 1971, U.S. Pat. No. 4,270,302 issued to Dandia on Jun. 2, 1981, and U.S. Pat. No. 5,779,517 issued to Clarke on Jul. 14, 1998. Additionally, some of these post and panel constructions use pegs at the end of the vertical posts, or the shape of the post itself, to define placement locations for components in the base component and provide structural rigidity as taught in U.S. Pat. No. 1,492,560 issued to Fisher on May 6, 1924, U.S. Pat. No. 3,571,965 issued to Gibb on Mar. 23, 1971, U.S. Pat. No. 4,270,302 issued to Dandia on Jun. 2, 1981 and U.S. Pat. No. 5,779,517 issued to Clarke on Jul. 14, 1998. 
     Finally, prior construction toys have offered limited assembly configurations due to specific purpose design components. As noted above, the single-piece base units have inherent limited design flexibility, because the construction is confined within the limits of the structural base. But, even sets with interlocking foundations have limitations to their expandability, requiring users to create within the realm supported by the specialized wall panel systems. A construction foundation layout developed by the user, connected and expanded at the user&#39;s discretion to specifically support the user&#39;s current creation, and allowing for addition without disassembly of present design offers benefits over the prior art. 
     BRIEF SUMMARY OF THE INVENTION 
     Accordingly, objects of my modular toy construction set invention, inter alia, are to provide: 
     flexibility of design 
     ease of assembly 
     stability in assembled components 
     compact disassembled storage 
     expandability in order to incorporate new components and create large projects 
     encouragement of creativity and imagination 
     Other objects of my invention will become evident throughout the reading of this application. 
     My invention is a modular toy construction system employing a frictional channel connection system, which supports combining an assortment of simple modular components without special tools. The system includes a series of post, panels, foundation pieces and connectors. Channels are pre-cut to allow the panels to slide into place, or for connectors to seat in the channels of adjacent pieces forming a clean interface between two channeled parts. Assembly in this fashion provides a friction fit, achieving substantial stability. This stability is present in both completed and partially assembled structures, allowing whole projects or sections thereof to be moved during construction with minimal risk of structural collapse. The system supports the possibilities of a wide variety of configurations and specialty pieces, which may be added to effect distinct characteristics, features and looks. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the top of a construction segment. 
     FIG. 2 is a perspective view of the bottom of the construction segment. 
     FIGS. 3 a-e  are perspective views of individual connectors. 
     FIG. 4 is a partial sectional view of the construction segment in FIG. 1, cut at line  4 — 4 . 
     FIG. 5 a  is an end sectional view of two interconnected posts. 
     FIG. 5 b  is a side partial sectional view of two interconnected posts. 
     FIG. 6 is a perspective view of the notched end of a notched post. 
     FIG. 7 is a perspective view of the pegged end of either a pegged post or a notched post. 
     FIG. 8 is a side partial sectional view of a perforation connector. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is a perspective view of an exemplary construction segment  1  buildable with this invention. Construction segment  1  shows various construction components and a method of employing those components. The structure is based on a modular foundation  2  comprised primarily of foundation pieces  10 , of various lengths. Foundation connectors, exemplified in FIG.  3 A through FIG. 3E, when employed in the connector receivers of adjoining pieces retain such pieces in fixed relationship, thereby providing a rigid integrated support structure. Likewise, the wall panels  30  are received by and snugly seated in the posts  20  and foundation pieces  10 . Such integrated support of adjoining pieces provides the stability for structures built using the system of the present invention. 
     The components may vary in scale sizes, with all sizes based on multiples of the base unit of length. The base unit of length is standard throughout compatible components. 
     FIG. 2 shows the underside of the exemplary embodiment of assembled modular foundation  2 . The exemplary foundation pieces  10  and foundation corner pieces  11  each include a foundation bottom groove  12  and multiple, uniformly spaced foundation channels  13 , foundation notches  14 , foundation perforations  15 , and foundation end channels  16  at the end of each piece for receiving the attachment of other components. Different embodiments of the invention may vary the number, orientation and spacing of the foundation bottom groove  12 , foundation channel  13 , foundation notches  14 , foundation perforations  15  or foundation end channels  16  receivers without departing from the scope of the invention. 
     In the exemplary embodiment, an angle  3  in the modular foundation  2  is achieved through the use of a foundation corner piece  11 . The exemplary foundation corner piece  11  forms a 90° angle  3 , but the invention supports angle  3  of greater and lesser degree. Referring to FIG.  1  and FIG. 2, another angle  4  in the modular foundation  2  is formed by attaching to the side of one foundation piece  10  with the end of another foundation piece  10   a.  In the exemplary embodiment of the modular foundation  2  this option is demonstrated at the junction of foundation pieces  10  and  10   a  in FIGS. 1 and 2, and creates an angle  4 . The angle  4  is again 90°, but here too the invention supports angles  4  of greater and lesser degree. 
     This angle  4  may be secured in various ways, either individually or in combination. Referring to FIGS. 1 and 4, one way is by the friction of the panels received and seated in the post channel  22 , foundation notch  14  and foundation top groove  17 . Another way, referring to FIG.  2  and FIG. 3B, is by use of a cross connector  41 , or other inlay connector (not shown) of suitable configuration, securely received and seated in the foundation bottom groove  12  and foundation channels  13 . 
     Referring to FIGS. 2 and 3A, double connector  40  seats in the foundation bottom grooves  12  of foundation piece  10  and  10   b,  and foundation corner piece  11 . Additionally, double corner connector  40  seats in a foundation channel  13  and foundation end channel  16  of each foundation piece  10  and  10   b.  All foundation pieces  10  and  10   b  and foundation corner piece  11  are all thereby integratedly secured. 
     Referring to FIG. 3B, cross connector  41  also secures corners in the modular foundation  2 . In the exemplary embodiment it secures the corner at the intersection of foundation pieces  10  and  10   a  creating angle  4 . While a first arm  41   a  of cross connector  41  seats in the foundation bottom groove  12  of foundation piece  10 , the second arm  41   b  seats in a foundation channel  13  of foundation piece  10  and extends in to the foundation bottom groove  12  of foundation piece  10   a.  Cross connector  41  can alternately be used to secure a foundation corner piece  11  with two foundation pieces  10  and  10   b.  The first arm  41   a  seats in the foundation bottom groove  12  of the first foundation piece  10  and extends into the foundation corner grooves  18 . The second arm  41   b  seats in the foundation bottom groove  12  of the second foundation piece  10   b  and extends into the other branch of the foundation corner groove  18 . 
     Referring to FIG.  2  and FIG. 3C, an alternative way to secure a corner is with single corner connector  42 . When the corner is made with a foundation corner piece  11 , the single corner connector  42  seats in the foundation corner groove  18  and extends to the foundation bottom grooves  12  of both the first foundation piece  10   c  and second foundation piece  10   d.  Alternately, single corner connector  42  may be used to secure foundation pieces  10  and  10   a  to form angle  4 . In that instance single corner connector  42  seats in foundation bottom groove  12  and foundation channel  13  of foundation piece  10  and extends to seat in foundation bottom groove  12  of foundation piece  10   a.    
     Linear connections of foundation pieces  10  can be made with double linear connectors  43  or linear perforation connectors  44 , as seen in FIG. 2, FIG.  3 D and FIG.  3 E. When double linear connector  43  is employed it seats in the foundation bottom groove  12 , and a foundation channel  13  and foundation end channel  16  of each foundation bottom piece  10  and  10   c.  When the linear perforation connector is employed it seats in a foundation end channel  16  and part of a foundation channel  13  of both foundation piece  10   a  and foundation piece  10   e.  Referring to FIGS. 2 and 3E, perforation tab  44   a  seats in a foundation perforation  15  in the last foundation channel  13  of foundation piece  10   a  and perforation tab  44   b  seats in a foundation perforation  15  in the last foundation channel  13  of foundation piece  10   e.  Other connectors (not shown) can be fashioned to be firmly received in specific sections of foundation bottom grooves  12 , foundation channels  13 , foundation perforations  15 , and foundation end channels  16 , and are anticipated by this invention. 
     It would be clear to one skilled in the art that angles  3  or  4  in FIGS. 1,  2  and  4 , being greater or lesser than 90°, may require some modification of the standard foundation piece  10 , post  20  and wall  30  shown. Such modifications may include angling the end of the foundation piece  10  to match the angle of the desired angle; a post  20  having three to six sides, with the angle between adjacent post channels  22  varying in degree, but less that 180°; or a wall  30  having a section angled so the section occupies a different plane that the primary part of the wall  30  and the intersection of the two planes are a line parallel with a side of wall  30 . In each of these cases the frictional stability of the resulting structure is maintained because the pieces fit snugly and cleanly abut on adjoining surfaces, and into corresponding receivers. 
     Referring to FIGS. 5 and 6, either a post  20  or a foundation piece  10 , may be securely connected to a second post  20   a  or foundation piece  10 , by means of an interconnetor piece  47 , which, being the same width and twice the depth as the post channel  22 , creates a firm abutment between the receivers of two similar components. 
     FIG. 8 shows an exemplary embodiment of a perforation connector  46  extending up through a foundation perforation  15  of foundation piece  10  to be securely seated in the post channel  22  of notched post  20 , the foundation channel  13  of foundation piece  10 , and the foundation bottom groove  12  of foundation piece  10   a.  In this manner the perforation connector secures the foundation piece  10  and foundation piece  10   a,  as well as anchoring notched post  20  in its position in foundation top groove  17 ; an important factor when post  20  forms a door or window frame with no solid wall panel  30  on the side opposite perforation connector  46 . Perforation connector  46  can be structured to have the portion situated above the level of the foundation perforation  15  be of double width so as to inlay in both post channels  22  of  10  and  10   a,  when they are appropriately positioned around a perforation, so as to act as an interconnector piece  47  shown in FIGS. 5 and 6. 
     Referring to FIGS. 2,  3 A through  3 E,  4 ,  5 A,  5 B, and  8 , the inlay pieces have a generally circular or rectangular cross section, sized to snugly fit into the depth and width of the foundation bottom groove  12 , foundation channel  13 , foundation notch  14 , foundation perforation  15 , foundation end channel  16  or post channel  22  connector receivers. Inlay connectors used in the bottom side of the foundation piece  10  or foundation corner piece  11  may seat entirely within the groove, so as to provide a flat surface when the foundation is oriented for construction. Such configuration provides the friction forces that produce the integrated support stability of the system of the present invention, while permitting the parts to be readily pried apart and reconfigured as the user desires. 
     Referring to FIGS. 1,  6  and  70 , the walls of construction segment  1  are formed from upright posts  20  with wall panels  30  received and secured in the post channels  22 , and received and seated in the foundation top groove  17 . Walls are made taller by connecting horizontal pegged posts  21   b  on the upper edge of a first wall panel  30   a,  engaging the peg  25  of both of the post pegged ends  23  into the post channel  22  of the vertical posts  20 . A second wall panel  30   b  can then be slid down the post channels  22  in the vertical posts  20 , to securely engage the post channel  22  in the horizontal pegged post  21   b.  Pegs  25  provide positioning guidance to ensure post  20  alignment. Pegs  25  are freely positionable in post channel  20  and are vertically supported by the underlying construction component, which in construction segment  1  is wall panel  30 . Wall components may be of varied sizes, based on the base unit of length for the particular set, while still staying modularly compatible. FIG. 1 illustrates a horizontal implementation of the half wall piece  30   c.    
     Adding a horizontal post  21   c  to the top of the second wall panel  30   b  allows for a stylized panel  50  to be received and secured in the post channel  22  of horizontal post  21   c  at the top of the construction segment  1 , providing stylistic features to the configuration. Using notched posts  21   a  in a vertical position places post notched ends  22  at the upper level of the construction segment  1 . This allows customized corner pieces (not shown) or pieces like stylized panel  50  to be secured in the corner&#39;s post end notch  24 . In addition to stylized components, embodiments of the invention may possess stylized textures (not shown) on the surfaces of the components, in order to provide the simulated look of particular construction materials. 
     In the exemplary embodiment the vertical posts  20  have post side notches  26  to accommodate upper floor segments  30   d.  Wall panels  30  become upper floor segments  30   d  if they are positioned horizontally. Embodiments of wall panels  30  with greater spans do not require as many horizontal connective posts  20 . 
     An alternative embodiment may employ positioning foundation piece  10  on top of wall panel  30  in order to develop a higher-level modular foundation  2 . Such a configuration would allow for balcony or loft structures to be incorporated into the structural designs. When the foundation bottom groove  12  and foundation channel  13  are the same dimensions as the foundation top groove  17 , the wall panels  30  will just as readily be received by and seat in one as the others. 
     The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.