Abstract:
A panel device for use with a plurality of connectors and rods with the rods connectable to the connectors is provided. The panel device comprises a substantially planar panel member having a plurality of sides. A groove is formed along each side of the panel member. A first groove edge is positioned along one side of the groove. A second groove edge is positioned on the other side of the groove with the second groove edge extending beyond the first groove edge wherein each rod is adapted to be inserted into the groove, the first groove edge and the second groove edge releasably maintaining the rod within the groove.

Description:
[0001]     The present application is a continuation-in-part of pending U.S. patent application Ser. No. 10/915,281, filed Aug. 10, 2004, which claims benefit of priority of U.S. Provisional Patent Application Ser. No. 60/495,454, filed on Aug. 15, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates generally to construction toys and, more particularly, the invention relates to an improved panel material and design for rod and connector construction toys.  
         [0004]     2. Description of the Prior Art  
         [0005]     Rod and connector style construction toys are well known in association with their respective trademarks, for example Tinkertoy™ manufactured by Playskool Inc., a division of Hasbro, Inc., FiddleStix™ manufactured by Toy N Things, and Zome™, manufactured by Zome Tool, Inc. These toys employ various linking means that permit connectors to join to rods to build composite, three-dimensional skeletal structures.  
         [0006]     The prior art construction toys include a plurality of connector elements to be arranged with a plurality of rod elements to form coherent, skeletal structures. Typically, cylindrical rods are provided in graduated lengths allowing rectangular and triangular structures to be assembled in graduated sizes. The connectors are provided in a variety of configurations, having anywhere from one to eight sockets on a single connector part. Connectors can also be designed to be associated as multi-part assemblies with sockets radiating in more than one plane. When assembled, the rods are firmly gripped within the socket, which serve to position the rod element in alignment with the socket axis.  
         [0007]     In the past, Playskool, a division of Hasbro, Inc., developed and marketed foam add-ons, called Foam Works™, with a TinkerToy™ construction set. However, these add-ons were not panels designed to fill skeletal structures. Toy N Things developed and marketed licensed add-on elements in a special Spiderman Fiddlestix™ construction set, but they also did not contain panels. The Gabriel, U.S. Pat. No. 4,129,975 had panel elements but these elements were not manufactured of foam and were either too costly to manufacture or resulted in heavily weighted structures unsuitable for children&#39;s play.  
         [0008]     It is an objective of the present invention to provide panels that can be molded into a wide variety of possible shapes including, but not limited to rectangles, triangles, trapezoids, and octagons.  
         [0009]     It is another objective of the present invention to provide panels that can be molded into three-dimensional objects.  
         [0010]     It is another objective of the present invention to provide such panels as to allow lateral insertion and removal without distorting the skeletal structure of said construction sets.  
         [0011]     It is another objective of the present invention to provide panels that are lightweight and safe for children to play with.  
         [0012]     It is a further objective of the present invention to provide such panels as to allow auxiliary elements to be attached thereto.  
         [0013]     It is a further objective of the present invention to provide such panels to flex to fit irregular planes.  
         [0014]     It is still a further objective of the present invention to provide panels that are economical to manufacture.  
         [0015]     For a more complete understanding of the above objectives and other features and advantages of the invention, reference should be made to the following detailed description of preferred embodiments and to the accompanying drawings.  
       SUMMARY  
       [0016]     The present invention is a panel device for use with a plurality of connectors and rods with the rods connectable to the connectors. The panel device comprises a substantially planar panel member having a plurality of sides. A groove is formed along each side of the panel member. A first groove edge is positioned along one side of the groove. A second groove edge is positioned on the other side of the groove with the second groove edge extending beyond the first groove edge wherein each rod is adapted to be inserted into the groove, the first groove edge and the second groove edge releasably maintaining the rod within the groove.  
         [0017]     In addition, the present invention is a method for constructing a toy set. The method comprises providing a plurality of rods, providing a plurality of connectors, connecting at least one rod to each connector forming a frame structure, providing a panel member, forming grooves on each edge of the panel member, compressing the panel member between the rods and the connectors within the frame, and receiving a rod in each of the grooves.  
         [0018]     The present invention further includes a toy set. The toy set comprises a plurality of rods and a plurality of connectors with each rod being receivable within at least one of the connectors. At least one compressible panel having edges is provided with grooves formed along the edges wherein the panel members are compressible between the rods and wherein each rod is receivable within at least one of the grooves. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is an exploded perspective illustrating a panel from assembled connector and rod elements, constructed in accordance with the present invention, with details of grooved recesses for the assembly of the panel;  
         [0020]      FIG. 2  is a top plan view illustrating a panel in assembly with the connector and rod elements, constructed in accordance with the present invention;  
         [0021]      FIG. 3  is a sectional view illustrating a panel between opposing rod elements taken along line A-A of  FIG. 2 ;  
         [0022]      FIG. 4  is a fragmentary sectional view illustrating a panel assembly with a rod element as taken within section  4  of  FIG. 3 ;  
         [0023]      FIG. 5  is a plan view illustrating a triangular panel assembly, constructed in accordance with the present invention;  
         [0024]      FIG. 6  is a perspective view illustrating the triangular panel in  FIG. 5 ;  
         [0025]      FIG. 7  is a perspective view illustrating a square panel, constructed in accordance with the present invention;  
         [0026]      FIG. 8  is a plan view illustrating a trapezoidal panel, constructed in accordance with the present invention;  
         [0027]      FIG. 9  is a fragmentary sectional view illustrating two panels connected to one rod at one hundred and eighty (180°) degrees;  
         [0028]      FIG. 10  is a fragmentary sectional view illustrating two panels connected to one rod at ninety (90°) degrees;  
         [0029]      FIG. 11  is an elevational side view illustrating a twisted rod and connector frame structure, constructed in accordance with the present invention;  
         [0030]      FIG. 12  is a perspective view illustrating a panel fitting the non-planar frame structure in  FIG. 11 ;  
         [0031]      FIG. 13  is a plan view illustrating a rectangular panel compressed to fit a trapezoidal area, in accordance with the present invention;  
         [0032]      FIG. 14  is a plan view illustrating the rectangular panel in  FIG. 13  fitting another trapezoidal area, in accordance with the present invention;  
         [0033]      FIG. 15  is a perspective view illustrating a planar panel curved to fit along a structure, in accordance with the present invention; and  
         [0034]      FIG. 16  is a perspective view illustrating a panel deformable over connectors along the rod, in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]     As illustrated in  FIGS. 1-16 , the present invention are panels, indicated generally at  10 , for connector and rod construction toy sets. Referring to  FIG. 1 , foam panels  14 , which are illustrated as having a consistent thickness, are adapted for spanning between sets of rods  12  located in an array corresponding to the particular shaped panel  14 . Located along edges of the panels  14  are grooves  18  shaped to match the radius of the rods  12  so that the panels  14  adhere to the rods  12  with the friction of contact. These side edges preferably extend the length of the panel  14  and serve to rigidify the panel  14  and to enclose the space.  
         [0036]     The panel  14  advantageously is preferably formed of foam by injection molding, using pellets, or cut to shape from pre-formed sheets of material. Polymeric foams come in many variants. One particular foam material has demonstrated the resilience needed is ethylene vinyl acetate (EVA) foam. EVA is closed-cell polymeric foam and can be manufactured in varying densities. In particular embodiments, the foam panel density and thickness may be altered to achieve design goals such as curving the panel  14  to create the sail of a ship or increasing density and thickness for the tire of a truck. During insertion and removal the foam material compresses to allow the panel  14  to pass between sets of rods  12  without distorting the structure.  
         [0037]     As illustrated in  FIG. 2 , the corner regions  16  of the panel are preferably contoured to match for cooperative association with various connector elements  17 .  
         [0038]     Referring to  FIGS. 3 and 4 , located along the panel front edge, adjacent to the groove, an offset projection  20  inhibits the panel from pushing through the frame structure during insertion. The length of the offset projection may vary and is dependent on usage, but typically would allow for a ⅛″ space between two parallel panels attached to the same rod to allow a panel to be gripped and removed as shown in  FIG. 9 . Located on the back edge, and also adjacent to the groove, is a beveled edge  22  which is adapted to make alignment during insertion easier and to allow two of the panels  14  to be attached to the same rod  12  perpendicularly. Preferably, the beveled edge  22  is approximately forty-five (45°) degrees.  
         [0039]      FIGS. 5 and 6  illustrate triangular panels  14  in the preferred form of the invention with the grooved portions  18  parallel to each respective rod  12  and the corner regions  16  similarly contoured to match for connectors  17  in the corner regions.  
         [0040]     With reference now to  FIG. 7  of the drawings, there is illustrated a square panel from the back with the groove  18 , offset projection  20 , and beveled edge  22  extending substantially entirely around the length the peripheral edges of said panel  14 .  
         [0041]     As illustrated in  FIG. 8 , a panel  14  is formed to fill a trapezoidal area, as defined by the connectors  10  and rods  12 , in which the corner regions  16   d ,  16   e , and  16   f  are sized and shaped to correspond to the configuration of the connector elements  17  in the trapezoidal space.  
         [0042]     As illustrated in  FIG. 10 , beveled edges allow two panels  14  to be attached to the same rod perpendicularly, forming and inside corner  24  where the foam material of the panel  14  compresses. As illustrated, a first surface of the panel  14  extends above the rod  12  while a second surface of the panel  14  is substantially flush with the rod.  
         [0043]      FIGS. 11 and 12  illustrate a resilient flat panel  14  deformed to fit an irregular plane. The rod  12   e  and connector  17   e  twisted substantially away from perpendicular alignment with the rod  12   f  and connector  17   f . The panel  14   e  flexes to fit the irregular frame structure without dislodging from said structure.  
         [0044]     With reference now to  FIGS. 13 and 14  of the drawings, in another preferred embodiment, the panels  14  can be formed of lower density foam to compress to fit between trapezoidal areas of the type that can be made by rotating one or more connectors  17  from perpendicular alignment. In  FIG. 13  the two connectors  17   g  are rotated 90 degrees from perpendicular alignment with two remaining connectors  17   f  in the trapezoid. The rods  12   f  and  12   g  are of the same length as are the rods  12   h . A rectangular panel  14   f  is compressed to fit the trapezoidal area without dislodging the structure. In  FIG. 14 , the same rectangular panel  14   f  used in  FIG. 13  spans a second trapezoidal area where a single connector  17   g  is turned 90 degrees from perpendicular alignment with the other three connectors  17   f.    
         [0045]     As illustrated in  FIG. 15 , the panel  14  is flexible to curve along a structure. As illustrated in  FIG. 16 , the panel  14  is adapted to deform over connectors  19  along the rod  16 . The rod holding the connectors  19  remains in the grooves. In fact, in a preferred embodiment, although not necessarily required, the rod  12  holding the connector  19  can remain completely positioned within the groove while deformed about the connector  19 . Furthermore, apertures  21  can be formed in the panels  14  for receiving additional pieces (not shown).  
         [0046]     In an alternative embodiment of the invention, panels  14  or any portion of the panels  14  can be color coordinated with rods of the construction sets. The color coordination of the panel edges assists the child in building a desired toy set.  
         [0047]     Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art, that the invention may be embodied in many other forms without departing from the clear teachings of the disclosure.  
       CONCLUSION  
       [0048]     The present invention is directed to the use of a novel and advantageous material for the design and construction of panel elements that are adapted and incorporated into a frame structure of the type described above. The panels are designed in a manner to allow enclosure or partial enclosure of frame structures to form an integral part of and thus enhance such structures. To this end, panel elements according to the invention are formed of foam material that is either injection molded or cut to shape from pre-formed sheets of the material. The panels may take a variety of polygonal shapes, most typically in the form of a square, rectangle or right isosceles triangle. The panel material is typically molded into a flat central area bounded by side edges. Adjacent side edges define corner regions, which are cut or molded for cooperative association with connector elements described above. At each panel edge there is molded an integral concave surface to match the corresponding rod element, being thus adapted for lateral snap-fit assembly between at least one opposing pair of rod elements.  
         [0049]     To advantage, during lateral insertion, the foam panel material compresses to fit between rod elements without forcing the rod elements out of their corresponding connectors. The panel elements of the invention can be readily incorporated in and/or removed from existing complex frame structures without the necessity of distorting the structure. Also to advantage, the panel will remain in place when the frame structure is twisted substantially outside of a flat plane as is often called for when building with said construction sets. The resiliency of the panel allows for it to be used in a plurality of instances, with a single panel fitting planar and non-planar areas in addition to rectangular and trapezoidal areas. When assembled, the panels are an integral part of the structure and can be utilized both in conjunction with and, in some cases, in place of a rod element.  
         [0050]     The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein, may be suitably practiced in the absence of the specific elements which are disclosed herein.