Patent Publication Number: US-8979608-B2

Title: Folded block structure and method for making

Description:
CROSS-REFERENCE TO OTHER APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/520,097 filed on 6 Jun. 2011 entitled “Paper Toy Building Block.” 
    
    
     BACKGROUND OF THE INVENTION 
     The invention is related generally to toy building sets comprising toy building elements and to toys which require assembly, more particularly to folded paperboard toy building blocks that are created by a user from flat sheets with predetermined fold lines and pre-cut lines to easily fold into hollow three-dimensional folded blocks. 
     Three-dimensional building blocks are commonly pre-built and made of solid, dense material (wood, plastic). These building elements are heavy and not easily transportable. 
     Paper toys designed to be cut, folded, and glued into a three-dimensional shape, are often pre-played, meaning that the toy has a predetermined result. This typically occurs when a paper toy is pre-printed with a particular character design providing a narrow scope for the resulting toy with a pre-conceived structural outcome (for example, make only a monkey) with no variation. In addition, regarding decorative designs on toys, the toys typically are offered finished and complete with an endpoint to the design already printed on the toy. The user, whether a child or an adult, often has no input on the decorative aspects of the toy. 
     SUMMARY OF THE INVENTION 
     An example of the invention is directed to a paperboard toy composed of fold-to-play hollow building blocks, typically referred to as folded blocks in this application, that are created from flat blanks on one or more shape sheets. The blanks detach from the shape sheet(s) without using separate cutting tools for detachment. The detached blanks can be built into three-dimensional shapes using a slit and tab connection system. The resulting folded blocks can be adhered to each other with, for example, provided adhesive dots, in any configuration as selected by the user to create a folded block structure. The folded blocks or the folded block structure, or both, can be decorated with, for example, stickers in any manner selected by the user, thereby enabling the creation of a wholly unique toy form by the user. 
     In some examples, the slit and tab connection allows the use of flat packed, easily detachable pre-scored, pre-die-cut shape sheets, which can be easily built into hollow folded blocks used to create one or more folded block structures. In some examples, the use of adhesive, such as adhesive dots, permits the user to join folded blocks to one another in various manners to make individualized folded block structures and thus toy forms unique to the user. Stickers or other ornamentation can be used to customize the exterior of the folded block structures. 
     The present invention has a versatile, open play aspect that allows the user to build a suggested folded block structure type of toy or a toy of their own imagination (ie: robot, car, tree, cake, etc.). 
     Various examples of the present invention provide for a building block, typically in the form of a paperboard folded block, which can provide for a fold-to-play experience from a pre-scored, perforated, die-cut flat piece of paperboard into hollow, three-dimensional building block with a slit and tab interface that requires no adhesive. Construction is easy and quick without the need for additional materials or tools and also provides a unique hands-on educational experience in the fields of design, math and engineering. 
     An example of a kit for creating a folded block structure comprises a set of blanks shaped to create a plurality of different shaped folded blocks without the need to use adhesive. Each blank includes sides, the sides having edges, the edges comprising side edges, tab edges and flap edges. The sides are joined to one another along adjacent ones of said side edges. Folds lines are at the side edges. The tab extends from each of the tab edges. Tab fold lines are at the tab edges. The flap extends from each of the flap edges. Flap fold lines are at the flap edges. A tab slit is at or near each of the flap folds lines, the tab slits being configured for receipt of corresponding ones of the tabs. In some examples, a plurality of tabs extends from at least one tab edge. In some examples, for each tab edge there is a corresponding flap edge. In some examples, the tab fold lines have ends and notches formed between the tabs and the tab edges at the ends of the tab fold lines. In some examples, the kit comprises adhesive elements placeable between a plurality of said folded blocks to create a folded block structure with said plurality of folded blocks adhesively secured to one another. 
     An example of a method for making a folded block structure kit for assembly by a user is carried out as follows. Shapes for a plurality of folded blocks are selected. The folded blocks are usable for the creation of at least one folded block structure without the need for the use of a cutting tool or an adhesive to create the folded blocks. For each folded block a blank is created, the blank comprising (1) sides corresponding to the side surfaces of the folded block, the sides having edges, the edges comprising side edges, tab edges and flap edges, the sides joined to one another along adjacent ones of said side edges, (2) tabs extending from each of the tab edges, and (3) flaps extending from each of the flap edges. Side folds lines are created along the side edges. Tab fold lines are created along the tab edges. Flap folds lines are created along the flap edges. Tab slits are formed at or near each of the flap folds lines. The tabs and the tab slits are configured for receipt of corresponding ones of the tabs by the tab slits. A folded block structure kit is assembled using the blanks for the folded blocks. In some examples, the method further includes creating instructions (1) to aid a user in the creation of the folded blocks, and (2) to aid user in the creation of a folded block structure from the folded blocks, the kit further comprising the instructions. Some examples further comprise providing the kit with an adhesive element, such as adhesive dots, for securing folded blocks, created by the user from the blanks, to one another to create a folded block structure. In some examples, the instructions creating step comprises instructing the user regarding the use of an adhesive element to create the folded block structure. 
     Other features, aspects and advantages of the present invention can be seen on review the drawing, the detailed description, and the claims which follow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a set of examples of folded blocks typical of the different shapes of folded blocks which can be made according to the invention. 
         FIG. 2  illustrates plan views of the set of blanks from which the folded blocks of  FIG. 1  are constructed. 
         FIG. 3  is an enlarged plan view of blank  13  of  FIG. 2 . 
         FIG. 4  illustrates a folded block structure in the form of a robot made using a number of the folded blocks of  FIG. 1 . 
         FIG. 5  is a plan view of a shape sheet including several of the blanks of  FIG. 2  which are used in the robot form of  FIG. 4 . 
         FIG. 6  is a plan view of a sticker sheet. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a number of different folded blocks identified as folded block  10 , folded block  11 , through folded block  25 . In this application, a folded block will be referred to generically as folded block FB. These are examples of different shapes of folded blocks FB that can be used with different examples of the present invention. Other shapes of folded blocks FB can also be used.  FIG. 2  shows plan views of blanks identified as blank  10 , blank  11 , through blank  25 . In this application, a blank will be referred to generically as blank B. Blanks  10 - 25  are used to make folded blocks  10 - 25  as will be described below. A number of different folded blocks FB can be combined to create a folded block structure. One example of a folded block structure is described below with reference to  FIG. 4 . Note that a kit for creating a folded block structure may include more folded blocks FB that are necessary for a particular folded block structure. 
     With specific reference to blank  13  of  FIG. 3 , blanks B include sides  28  having different types of edges, referred to as side edges  30 , tab edges  32  and flap edges  34 . Sides  28  are joined to one another, typically as a continuous sheet of material, along side edges  30 . Pre-creased side fold lines  36  are preferably formed along the joined side edges  30 . Tabs  38  extend from tab edges  32  along pre-creased tab fold lines  40 . Flaps  44  extend from flap edges  34  along pre-creased flap fold lines  46 . 
     Tab slits  50  are formed at or near flap fold lines  46  and are configured for receipt of corresponding tabs  38  during the construction of folded blocks FB from blanks B. To facilitate this interaction, tabs  38  have notches  52  at either end of the tab. In this example, longer tabs are about 0.4255″×0.1863″ with notches of about 0.06″×0.15″, and shorter tabs are about 0.243″×0.1884 inch with notches of about 0.035″×0.15″. In this example, the longer tab slits  50  have dimensions of about 0.3735 inch long by 0.015 inch wide while the shorter tab slits  50  have a length of 0.2 inch long×0.015 inch wide. These dimensions have been found suitable for paperboard having a thickness of about 300 g/m 2  with the sides  28  having lengths and widths in the range of about ½ inch to about 5 inches according to the particular shape. 
     Examples discussed herein are typically made of a thick paper-based material, typically referred to as paperboard. The material is foldable and can be creased and slit. It is also recyclable. The material can be single ply or multi ply. It can also be only partially paper-based or it can be made of a material without any paper at all but which can be folded and manipulated like paper-based paperboard. Therefore, the term paperboard includes materials suitable for creating folded blocks FB from blanks B. Is expected that folded blocks FB can be provided in a range of sizes, such as small, medium, large and extra-large having one maximum dimension of, for example, 1 inch, 1.5 inches, 2 inches, and 2.5 inches. Other sizes and ranges of sizes can also be used. Also, a particular folded block structure, such as folded block structure  58  of  FIG. 4 , can be, and will typically be, made using a range of different sizes of folded blocks FB. 
       FIG. 4  illustrates a folded block structure  58  in the form of a stylized robot made from a number of folded blocks FB, the folded blocks made from associate blanks B. Specifically, and as illustrated in  FIG. 4 , two small folded blocks  17  (ears), one small folded block  16  (antenna), one large folded block  24  (head), five small folded blocks  15  (robot chest armor), two small folded blocks  24  (arms), two small folded blocks  20  (shoulders), two small folded block  13  (hands), and two small folded block  13  (feet), were used in constructing structure  58 . The specific blanks B corresponding to some of these folded blocks FB are shown in more detail in  FIG. 5 . 
       FIG. 5  illustrates an example of what are referred to as shape sheets  62 . The shape sheets contain blanks B sharply cut by appropriate processing means so that blanks B can be easily detached from the shape sheet without forcing a user to use a separate cutting tool. This differs from a conventional method of having a user directly cutting the shapes, by means of a cutting tool such as scissors and the like, which often does not make the edges of the cut blanks sharp, clear and accurate. Further, when blanks B are inexactly cut, the shapes may not be available for building the shape into an accurately created three dimensional, hollow folded block, thereby impeding the completion of the toy form itself. However, in the case of the shape sheet  62  for a blank B according to the present invention, such a problem has been overcome. The processing means mentioned above is preferably comprised of a mold knife. Using a mold knife as the processing means for cutting out the blanks B is particularly appropriate when the sheet material is made of recyclable paperboard, such as heavy paper or cardboard stock. The mold knife process also makes viable the tab/tab slits aspect of examples of the invention. 
     One example of a procedure for making folded block structure  58  is as follows. The user first removes a blank B, such as small blank  13 , from a shape sheet  62  to create small folded block  13  serving as one of the robot&#39;s hands. In some examples, blanks B have ornamentation or other designs on one or both sides. This permits the user to select which side is to be exposed for use in creating the robot or other creation. The user then pre-folds the blank B along the side fold lines  36 , tab fold lines  40  and flap fold lines  46 . This pre-folding helps to begin placing blank B into its folded shape. In some examples, tabs  38  and the corresponding flaps  44  having the tab slits  50 , which will receive the tabs, are marked to help guide the construction of the folded blocks FB. As shown in  FIG. 3 , tabs  38  may be marked with, for example, reference characters A, B, C, etc. and the tab slits  50  to which the tabs will be secured may be marked with like characters A, B, C, etc. Tabs  38  and tab slits  50  create a slit and tab system thereby connecting two sides  28  of the blank B at their tab edges  32  and flap edges  34 , transforming the flat two-dimensional shape into a three dimensional hollow block. This procedure is repeated for each of the folded blocks FB needed to make a particular folded block structure  58 , such as a robot shown in  FIG. 4 . Depending on the length of an edge, more than one tab may be used along one edge. However, folded blocks FB are constructed without the need for adhesives or other securing agents. Tabs  38  and tab slits  50  provide the necessary means for maintaining the folded blocks FB in their three-dimensional shapes. 
     After the folded blocks FB necessary to create the particular folded block structure  58  are created, they are adhered to one another typically using double-sided adhesive dots. Adhesive dots are conventional circles of adhesive captured between two release sheets. Other types of adhesive elements, which may be removable or permanent, may also be used. In some examples, adhesion may be through the use of magnetic adhesive elements. 
     Additional ornamentation for decoration and customization may be added to the individual folded blocks FB or to the finished folded block structure  58 , or to both. The additional ornamentation may be in the form of stickers removed from a sheet  66  of stickers  68 , an example of which is shown in  FIG. 6 . Elements of the accessory sticker sheet  66  have cut lines created by a processing means so as to allow stickers  68  to be easily detached from sticker sheet  66  without using a separate cutting tool. In some examples, stickers  68  are arranged to the appropriate scale and size specific to the particular folded block structure  58  to be made. Sticker sheet  66  may be modified in various manners without departing form the technical idea or concept of the present invention. For example, sticker sheet  66  may be arranged differently depending on, for example, the size and shape of the folded blocks FB, or depending on a particular folded block structure  58  for which stickers  68  are designed. 
     In some examples, the various components required to create folded block structures are provided in the form of a kit. One example of a kit includes one or more shape sheets  62  containing a number of different blanks B. In this example, the kit may also include instructions for which blanks B will be needed to create a particular folded block structure  58 , the folded block structure preferably shown in a completely assembled form and, optionally, shown in a series of partially completed forms to aid construction. In addition, the kit, in some examples, may include a supply of adhesive dots and a sheet of stickers for ornamentation. The kit may include only the blanks B necessary to create one or more specific folded block structures  58 . Alternatively, the kit may include extra blanks B or the kit may include a variety of blanks B without any instructions on making a particular folded block structure  58 . 
     As is apparent form the above description, folded block structures  58  are fabricated with the use of one or more shape sheets  62  on which a plurality of blanks B sharply cut by a processing means are arranged, and thus the blanks B for the toy are easily detached from the shape sheets  62 . In addition, the detached blank B transforms from a flat two dimensional shape into a three dimensional hollow block, and accordingly, the present invention is effective in enhancing the user&#39;s dimensional and spatial thinking abilities as well as general math and engineering skills. 
     It is the intention of this invention to create an all inclusive user experience whereby no outside tools or other materials are typically needed to build a paper toy form in the form of folded blocks FB. 
     The shape sheets  62 , the flattened two-dimensional format of the blanks B, and the various shapes and sizes of the shapes can be modified in various manners without departing form the technical idea or concept for the present invention. For example, the blanks B may be provided in a single shape sheet  62  or a plurality of shape sheets  62  depending on the size, shape and complexity of the folded block structure  58 . The order or form of the blanks B arranged on the shape sheets  62  may also be modified as necessary. The number of the blanks B may be increased or decreased depending on the size and form of the folded block structure  58  selected. 
     One embodiment of the present invention described above, a robot, was referred to as an example for a folded block structure  58 , sometimes referred to as a toy form. However, it is evident to one skilled in the art that the present invention can be applied to forms of all kinds including but not limited to a wide variety of animals, objects, automobiles, etc. 
     Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing form the scope and spirit of the inventions as disclosed in the accompanying claims.