Patent Publication Number: US-7588476-B2

Title: Hinged connector for multi-part construction toy

Description:
RELATED CASES 
   The invention of this application is related to Joel I. Glickman U.S. Pat. Nos. 5,061,219, 5,137,486, 5,199,919, and 5,350,331. The disclosures of these patents are incorporated by reference. 
   BACKGROUND OF THE INVENTION 
   In the Glickman U.S. Pat. No. 5,061,219, there is disclosed a multi-part construction toy utilizing a novel form of rod and connector system which enables rods to be joined with connectors by a lateral, snap-in motion into sockets provided by the connector elements. In the subsequent Glickman U.S. Pat. Nos. 5,137,486 and 5,199,919, there are disclosed modified forms of connector elements in which two connector parts are joined together in a fixed relation, with one connector part being in a plane oriented at right angles to the plane of the other connector part. The resulting connector enables rods to be assembled in two planes, facilitating the construction of three-dimensional structures. Construction toy sets incorporating these features are sold commercially under the trademark K&#39;NEX by K&#39;nex Industries, Inc., Hatfield, Pa. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a novel and improved form of connector element, which is compatible with the existing K&#39;NEX multi-part construction toy system, wherein a connector element is formed of two parts, hinged together for pivotal movement. Among other advantages, the hinged connector element facilitates the initial construction of three-dimensional structures entirely or in part in two-dimensional form. Thus, as set forth in co-pending application Ser. No. 11/049,809, filed Feb. 3, 2005, it is advantageous at times to assemble a structure in two-dimensional form directly over a full-size, two-dimensional plan, such that a child can place parts directly on top of a full-size illustration thereof on the underlying two-dimensional plan. After completing a two-dimensional assembly in this manner, portions of it can be easily pivoted out of the initial assembly plane, by means of the hinged connector of the invention, in order to convert the initial two-dimensional structure to a three-dimensional form. The hinged connector elements also enable structures to accommodate special forms of pivotal motion between adjacent portions of an assembled structure. 
   In a particularly preferred embodiment of the invention, a connector element, comprised of two hingedly connected parts, is formed with eight rod-engaging sockets. Four sockets are provided on each of the hinged connector parts, with each socket being disposed at an angle of 45 degrees to its neighbor. The arrangement is such that the hinged connector is arranged with its sections in a common plane, the connector corresponds generally in size and function to the basic eight-socket connector of a standard K&#39;NEX set, as illustrated in the before-mentioned Glickman U.S. Pat. No. 5,061,219. In the device of the present invention, however, the two connector parts can be disposed at any angle between zero and 90 degrees in either direction (180 degrees overall pivoting action). Although the preferred connector element described herein is illustrated as being formed with eight sockets, it will be understood and will become evident that pivoted connector elements according to the invention may be formed with a different number of rod-engaging sockets, if desired. 
   To particular advantage, the connector element of the invention is designed so that each of the two parts forming the assembled connector is of identical construction, such that any two connector half sections can be joined together to form an assembled, pivoted connector element. To this end, each of the connector half sections is provided along one edge thereof with one male hinge element and one female hinge element, with the two hinge elements being axially aligned. The female hinge elements preferably are in the form of open-sided cylinders, with cylindrically contoured walls extending over an angle somewhat in excess of 180 degrees. This allows the female hinge elements to be easily joined with the male hinge elements with a snap-together action. 
   For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of a preferred embodiment, and to the accompanying drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front elevational view of an assembled, two-part hinged connector element according to the invention. 
       FIG. 2  is a back elevational view of the assembled connector of  FIG. 1 . 
       FIG. 3  is a perspective view of the connector of  FIGS. 1 and 2 , illustrating the two-part connector with its individual half sections disposed at an angle of 90 degrees. 
       FIG. 4  is a back elevational view of a single connector half section constructed according to the invention. 
       FIGS. 5 and 6  are top and bottom plan views respectively of the connector half section of  FIG. 4 . 
       FIG. 7  is a cross sectional view as taken generally on line  7 - 7  of  FIG. 4 . 
       FIG. 8  is an end elevational view of the connector half section of  FIG. 4 . 
       FIG. 9  is a cross sectional view as taken generally on line  9 - 9  of  FIG. 4 . 
   

   DESCRIPTION OF A PREFERRED EMBODIMENT 
   Referring now to the drawings, and initially to  FIGS. 4-9  thereof, the reference numeral  10  designates generally a connector half section constructed in accordance with the invention. The half section  10  includes a body portion  11  which forms four sides of an octagon comprised of walls  12 - 15 . The four walls  12 - 15  form bottom walls of a plurality of rod-engaging sockets  16 - 19  respectively, which extend radially outward from a common center point  20 . A base wall  21  connects the opposite ends of the octagon walls  12 - 15 , extending parallel to a hinge axis  22  which extends through the common center point  20 . 
   The connector half section  10  is formed with a plurality of rod-gripping arms  23 - 25 , with arms  24 ,  25  being located at the opposite end extremities of the connector section. Functionally, the gripping arms are the same as set forth in the Glickman U.S. Pat. No. 5,061,219. In this respect, each of the gripping arms  23 ,  25  of a socket-forming pair includes a groove  26  extending along the radial axis of the socket. Laterally outer portions of the gripping arms are provided with angled lead-in surfaces  27  to facilitate a lateral snap-in assembly of a rod element  28  ( FIG. 1 ). Each of the gripping arms  23 - 25  is provided with an inwardly projecting rib  29  extending transversely across the width of the socket, for engagement with a correspondingly contoured annular groove  30  in the rod. An end flange  31  of the rod seats in a recess  32  in the bottom of each socket, preferably urged inwardly against the bottom wall  12 - 15  by reason of cooperation between the transverse projections  29  and the annular groove  30 . 
   In the illustrated and preferred embodiment of the invention, each of the connector half sections  10  is provided with one male hinge element  32  and one female hinge element  33 . The female hinge element, shown in profile in  FIGS. 7 and 8 , preferably is in the form of an open-sided cylinder, with the open side  34  thereof facing to one side of the half section  10 . The wall  35  of the cylinder is integrally attached at  36  to the base wall  21  of the connector half section, as shown in  FIGS. 7 and 8 . The cylindrical wall  35  is aligned along the axis  22 , which forms the hinge axis of a pair of assembled half sections. As shown in  FIG. 4 , the female hinge element  33  is located at one end of the base wall  21 , which may sometimes be referred to as the diametral edge of the half section. 
   The male hinge element  32  is located at the opposite end of the base wall  21 , axially aligned with the female hinge element  33  but spaced slightly therefrom. The male hinge element is anchored to the body of the half section by an end plate  37  at one end, and by the socket bottom wall  15 , at the other end. 
   To advantage, the male hinge element  32  has an effectively cylindrical cross section corresponding to the internal cylindrical cross section of the female hinge element  33 . In the specifically illustrated form of the invention, the male hinge element comprises a central planar core  38 , preferably aligned with planes formed by opposite side surfaces  39 ,  40  of a connector half section. 
   If desired, the male hinge part  32  may be produced in the form of a solid cylinder. However, both weight and material can be saved by forming the male hinge element as being “effectively cylindrical” rather than in the form of a solid cylinder. To this end, the hinge element  32  is formed with a plurality of thin spacer elements  41  extending at an angle along the central panel  38 . Viewed from the side, as in  FIGS. 2 and 4 , the spacer elements  41  appear in a zigzag fashion. As viewed axially, however, the spacer elements  41  would define a circular outline corresponding substantially to the internal diameter of the female hinge element  33 . 
   As is evident in  FIG. 4 , a space  42  is provided between the core panel  38  of the male hinge element and the base wall  21 . The length and width of the space  42  is such that it can closely receive the side wall  35  of a female hinge element  33  of another connector half section, in order to accommodate the desired hinging action. 
   In accordance with one aspect of the invention, a pair of identical half sections, as shown in  FIG. 4 , may be connected together to form a hinged connector element  44 , as shown in  FIGS. 1 and 2 . The assembly is accomplished by orienting the two half sections with the principal planes thereof more or less at right angles, and with the axis of one half section tilted slightly with respect to the other (twist angle). This enables the open sides of the two cylindrically contoured female hinge elements  33  to be forced over the respective male elements  32  with a snap-together action. In this respect, in the illustrated form of the invention, the cylindrical wall  35  of the female hinge element advantageously encompasses an included angle of about 270 degrees. This requires the side openings  34  of the female hinge elements to be forced open in order to fit over the effectively cylindrically contoured elements  32 . Once assembled, the two connector half sections are, for all practical purposes, permanently assembled, although they may in fact be disassembled by pivoting the two half sections at an angle of around 90 degrees and imparting a twist action between the two halves. The disassembly is essentially the reverse of the assembly operation. It will be noted in  FIGS. 1 and 2  that, in the assembled form of two connector half sections, the female hinge elements  33  of each half section face in the same direction. The assembled half sections have a range of pivoting action of 180 degrees, or 90 degrees on either side of the coplanar configuration shown in  FIGS. 1 and 2 . 
   With reference to  FIGS. 1 and 2 , it will be noted that the rod-engaging sockets  19  at one end of each half section are aligned axially with respect to the hinge elements  32 ,  33 . Accordingly, the hinging action of the respective half sections, one with respect to the other, will take place about the axes of any rods engaged by these sockets. 
   In the illustrated form of the invention, the connector elements are intended for use in connection with a standard K&#39;NEX multi-part construction toy set, and are dimensioned accordingly. It will be understood, however, that specific dimensions referred herein are for illustrated purposes only, and are not in any way limiting of the invention. For a standard K&#39;NEX construction toy set, the combined connector  44  ( FIGS. 1 and 2 ) typically may have a thickness on the order of ¼ inch. The two-part connector element is more or less circular in its overall configuration, with an overall diameter of around 1.5 inches. The two half sections, accordingly, are formed with somewhat of a semi-circular configuration, for an assembled connector of generally circular configuration, as will be understood. 
   To accommodate pivoting action between two connected half sections  10 , about the pivot axis  22 , the gripping arm  25 , at the outer side of the axially aligned rod-engaging socket  19 , is formed of a narrower width than the several rod-engaging arms  23 . This can be seen in  FIGS. 8 and 9 . The bottom walls  15  of the sockets  19  likewise are tapered from the rod-engaging arm  23  on one side thereof to the arm  25  on the opposite side thereof. This narrower configuration of the rod gripping arms  25  and the tapered bottom walls  15  allows the connected half sections to rotate without interference between the base of the rod gripping arm  24  of one half section with the rod gripping element  25  of the other. At its narrowest point, along its outside edges, the width of the gripping arm  25  may be approximately half the overall thickness of the connector element section. To impart additional gripping strength to the narrowed rod gripping arm  25 , a reinforcing rib  45  may be provided at the base thereof, as shown in  FIGS. 4 and 9 . The gripping arm  24 , at the opposite end of the connector half section, is recessed slightly at  46  ( FIG. 4 ) to clear the reinforcing rib  45  of an opposite half section, when the two are connected for rotation. 
   Preferably, the connector half sections  10  are formed by injection molding, with a high strength plastic material. One preferred material is “Celcon” acetal copolymer, marketed by Ticona, a Division of Celanese. 
   The connector element of the invention extends the variety of structures that can be assembled and used with a K&#39;NEX rod and connector construction toy set. Among other things, the pivoting connector element enables structures to be assembled with adjacent portions at various angles. Moreover, in certain cases, it may be desirable to assemble a three-dimensional structure, or portions of a three-dimensional structure, in two-dimensional form, directly upon a full-size plan, and thereafter convert the two-dimensional structure to a three-dimensional form. The pivoting connector element is extremely useful in such assembly procedures, inasmuch as it allows a portion of a two-dimensional structure to be simply pivoted into a three-dimensional configuration after initial assembly. 
   The pivoting connector of the invention is easily assembled from using two identical connector half sections, which are easily snapped together to form a semi-permanent connection. Once assembled by the user, a hinged connector typically will remain in its assembled condition, although it may easily be disassembled if desired. 
   It should be understood, of course, that the specific forms of the invention herein illustrated and described are intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.