Patent Publication Number: US-2020276614-A1

Title: Apparatus and method for sorting modular building blocks

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority to prior-filed and co-pending provisional patent application Ser. No. 62/811,776, filed Feb. 28, 2019 by Charles Dustin Janes, the entirety of which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Technical Field 
     The present device relates to the field of sorting technology and more specifically to the field of sorting technologies for modular building blocks. 
     Background 
     It is common today for children and adults to build from kits using one or more modular building block systems. Lego® brand (modular building blocks) and Duplo® brand (modular building blocks) are but two examples of many suppliers/brands of modular building blocks that come in a variety of sizes, shapes and colors. When using the pieces of modular construction sets it is often difficult and/or time consuming to locate pieces having the specific geometric properties that a user desires as the pieces are commonly mixed together and stored in single container. Alternately, some users may categorize and separate the pieces into containers having common geometric properties. However, this is time consuming. Additionally, construction of new models from a set of mixed modular blocks can be frustrating and/or time consuming. What is needed is a modular building block sorter that is capable of segregating blocks having differing geometric properties. 
     SUMMARY 
     A modular building block sorter comprising a housing having at least two sides and a base. The housing can also include at least one perforated surface adapted to selectively engage with said at least two sides of said housing. The base of the housing can also comprise a first portion and a second portion wherein said base is other than substantially planar. 
     Implementations may include one or more of the following features: The modular building block sorter can also include a base wherein the base includes an arc; the modular building block sorter can also include a base wherein said the base includes at least one discontinuity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further details of the present device are explained with the help of the attached drawings in which: 
         FIG. 1  depicts an embodiment of a modular building block sorter 
         FIGS. 2 a  and 2 b    depict an alternate embodiment of a modular building block sorter 
         FIGS. 3 a  and 3 b    depict an alternate embodiment of a modular building block sorter 
         FIGS. 4 a  and 4 b    depict an alternate embodiment of a modular building block sorter 
         FIGS. 5 a  and 5 b    depict an alternate embodiment of a modular building block sorter 
         FIGS. 6 a  and 6 b    depict an alternate embodiment of a modular building block sorter 
         FIGS. 7 a -9 b    depict alternate embodiments of base configurations of modular building block sorters. 
         FIGS. 10 a -10 i    depict embodiments of apertures in the perforated surfaces. 
         FIG. 11  depicts a method of sorting modular building blocks. 
     
    
    
     DETAILED DESCRIPTION 
     As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
     Modular building blocks come in various sizes ranging from very large pieces to very small pieces. Moreover, modular building blocks also generally have protrusions and complimentary recesses laid out in an a×b grid pattern for each piece where “a” and “b” can be any known, convenient and/or desired numbers. By way of non-limiting example, pieces can be 4×0.4, 4×3 (or 3×4), 4×0.2 (or 2×4), 4×1 (or 1×4), 3×0.3, 3×0.2 (or 2×3), 3×1 (or 1×3) and so forth, down to 1×1 and/or smaller pieces. 
       FIG. 1  depicts an embodiment of a modular building block sorter  100 . In the embodiment depicted in  FIG. 1 , the modular block sorter  100  comprises a housing (case)  102 , a plurality of trays  104   106   108   110   112 , a substantially solid surface  114 , a plurality of perforated surfaces  116   118   120   122 , a retention device  124  a base  126  having a curved lower surface  128 . In some embodiments, one or more of the trays  104   106   108   110   112  and/or the substantially solid surface  114  and/or the plurality of perforated surfaces  116   118   120   122  and/or the retention device  124  can be absent. Moreover, in some embodiments, the retention device can comprise a locking mechanism such that when in a locked state one or more of the trays  104   106   108   110   112  can be constrained within the housing  102  until unlocked and/or one or more of the trays  104   106   108   110   112  can be restricted from engaging with the housing  102 . Additionally, in some embodiments, the housing  102  can comprise a handle  130 . 
     In the embodiment depicted in  FIG. 1 , the housing  102  can have any known, convenient and/or desired shape and/or geometry and the trays  104   106   108   110   112  can have any known, convenient and/or desired complimentary geometry such that the trays  104   106   108   110   112  can be selectively supported with the housing  102 . Additionally, the base  126  can have any known convenient and/or desired curvature/arc as the curved lower surface  128 . 
     In the embodiment depicted in  FIG. 1 , one or more of the plurality of trays  104   106   108   110   112  can be removably coupled with the housing. In some embodiments, each of the perforated surfaces  116   118   120   122  and the substantially solid surface  114  can be integral with a corresponding one of the plurality of trays  104   106   108   110   112 . However, in alternate embodiments, the each of the perforated surfaces  116   118   120   122  and the substantially solid surface  114  can be selectively and removably coupled with any one or more of the trays  104   106   108   110   112 . That is, each of the perforated surfaces  116   118   120   122  and the substantially solid surface  114  can be selectively coupled with any one of each of the trays  104   106   108   110   112 . While depicted in  FIG. 1  as housing 5 trays, in alternate embodiments the housing  102  can house any known, convenient and/or desired number of trays  104   106   108   110   112 , selectively coupled with any known, convenient and/or desired number of perforated surfaces  116   118   120   122  and/or substantially solid surface(s)  114 . 
     In some embodiments, each of the perforated surfaces  116   118   120   122  can comprise apertures adapted and configured to allow modular blocks smaller than specified dimensions to pass through the aperture. By way of non-limiting example (wherein in z is any number), in some embodiments, one of the perforated surfaces  116  can allow modular blocks smaller than 4×z to pass through the apertures in the perforated surface  116 , a second one of the perforated surfaces  118  can allow modular blocks smaller than 3×z to pass through the apertures in the perforated surface  118 , a third one of the perforated surfaces  120  can allow modular blocks smaller than 2×z to pass through the apertures in the perforated surface  120 , a fourth one of the perforated surfaces  122  can allow modular blocks smaller than 1×z to pass through the apertures in the perforated surface  122  and the substantially solid surface  114  can be configures such that no modular blocks will pass through the substantially solid surface  114 . 
     In some embodiments, the perforated surfaces  116   118   120   122  and the substantially solid surface  114  can be associated with trays  104   106   108   110   112 , such that the perforated surface with the largest apertures is associated with the tray located farthest from the base  126  of the housing  102 , the perforated surface with the next largest apertures is associated with the tray located second farthest from the base  126  of the housing  102 , the perforated surface with the next largest apertures is associated with the tray located third farthest from the base  126  of the housing  102 , the perforated surface with the next smallest apertures is associated with the tray located second closest to the base  126  of the housing  102  and the substantially solid surface  114  is associated with the tray closes to the base  126  of the housing  102 . 
     The retention device  124  can be a rod that passing across an open face of the housing  102  that inhibits the trays  104   106   108   110   112  from disengaging from the housing  102 . However, in alternate embodiment the retention device  124  can be any known, convenient and/or desired apparatus that inhibits the trays  104   106   108   110   112  from disengaging from the housing  102 . 
     In operation, trays  104   106   108   110   112  can be installed in the housing and the substantially solid surface associated with the tray closes to the base  126  and with perforated surfaces  116   118   120   122  having increasingly larger apertures from lowest positioned tray  106  (above the substantially solid surface  114 ) to highest positioned tray  112 . The trays  104   106   108   110   112  can then be secured within the housing by the retention device  124 . The housing can then be agitated by rocking the housing while the base  126  is kept in contact with a surface on which the base  126  is standing, cause pieces smaller than the various aperture sizes to pass through the apertures in the various perforated surfaces  116   118   120   122  and thereby segregating the modular building blocks by size with larger pieces in the top tray and smallest pieces in the bottom tray (and progressively smaller pieces being segregated largest to smallest, top to bottom). 
       FIGS. 2 a  and 2 b    depict an alternate embodiment of a modular building block sorter. In the embodiment depicted in  FIGS. 2 a  and 2 b   , the base  126  has the shape of a truncated arc comprised of a substantially flat surface  202  and two arced surfaces  204   a    204   b . In use, the housing  102  is stable when vertical and resting on the substantially flat surface  202  and when agitated or rocked over the discontinuity  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuity  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 3 a  and 3 b    depict an alternate embodiment of a modular building block sorter. In the embodiment depicted in  FIGS. 3 a  and 3 b   , the base  126  has the cross-sectional shape of a truncated triangle comprised of a substantially flat surface  202  and two angled substantially planar surfaces  302   a    302   b . In use, the housing  102  is stable when vertical and resting on the substantially flat surface  202  and when agitated or rocked over the discontinuity  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuity  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 4 a  and 4 b    depict an alternate embodiment of a modular building block sorter. In the embodiment depicted in  FIGS. 4 a  and 4 b   , the base  126  has the cross-sectional shape of two arc regions  204   a    204   b  with a central inverted arc cutout  402 . In use, the housing  102  is stable when vertical and resting on the discontinuities  206  between the arc regions  204   a    204   b  and the central inverted arc cutout  402  and when agitated or rocked over the discontinuities  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuities  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 5 a  and 5 b    depict an alternate embodiment of a modular building block sorter. In the embodiment depicted in  FIGS. 5 a  and 5 b   , the base  126  has the cross-sectional shape of two substantially planar regions  302   a    302   b  with a central inverted arc cutout  402 . In use, the housing  102  is stable when vertical and resting on the discontinuities  206  between the substantially planar regions  302   a    302   b  and the central inverted arc cutout  402  and when agitated or rocked over the discontinuities  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuities  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 6 a  and 6 b    depict an alternate embodiment of a modular building block sorter. In the embodiment depicted in  FIGS. 6 a  and 6 b   , the base  126  has  2   a  and overall arced cross-sectional shape  128  with two protrusions  602   a    602   b  along the length of the arc  128 . In some embodiments, the protrusions  602   a    602   b  can be positioned at the exterior boundary(ies) of the base  126  of the housing  102 . However, in alternate embodiments, the protrusions  602   a    602   b  can be positioned in any known, convenient and/or desired position(s) on the base  126  of the housing  102  and can run any known, convenient and/or desired length of the housing  102 . In use, the housing  102  is stable when vertical and resting on a portion of the arc  128  and at least one of the protrusions  602   a    602   b  and when agitated or rocked over one or more of the protrusions  602   a    602   b  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the protrusions  602   a    602   b  which create surface discontinuities in the base  126  and arc  128 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked over the protrusions  602   a    602   b /across the discontinuities the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 7 a -9 b    depict bottom views of alternate embodiments of base  126  configurations of the modular building block sorter  100 . 
     In the embodiment depicted in  FIGS. 7 a  and 7 b    there are depicted a substantially planar surface  702  and four planar surfaces  750  such that the base  126  has the shape of a truncated 4-sided pyramid, thus creating 8 discontinuities  206 . When agitated or rocked over the discontinuities  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuities  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
     In the embodiment depicted in  FIG. 8 a    there are depicted a substantially planar surface  702  and a single curved surface  722  such that the base  126  has the shape of a truncated dome having a circular discontinuity  206 . When agitated or rocked over the discontinuity  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuity  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration 
     In the embodiment depicted in  FIG. 8 b    there are depicted a substantially planar surface  702  and four planar surfaces  750  such that the base  126  has the shape of a truncated 4-sided pyramid, thus creating 8 discontinuities  206 . When agitated or rocked over the discontinuities  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuities  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
     In the embodiment depicted in  FIGS. 9 a  and 9 b    there are depicted a substantially planar surface  702  and a plurality of planar surfaces  750  such that the base  126  has the shape of a truncated polyhedral, thus creating any known, convenient and/or desired number of discontinuities  206 . When agitated or rocked over the discontinuities  206  the housing  102 , trays  104   106   108   110   112 , various perforated surfaces  116   118   120   122  and substantially solid surface  114  are subject to vertical acceleration due to the transition over the discontinuity  206 . Thus, when modular building blocks are introduced into the top tray  112  and the housing  102  agitated/rocked across the discontinuities  206  the modular building blocks translate in the horizontal plane and vertically due to the vertical component of acceleration. 
       FIGS. 10 a -10 i    depict top view embodiments of apertures  1000  in the perforated surfaces  116   118   120   122 . In the embodiments depicted in  FIGS. 10 a  and 10 f   , the aperture  1000  can comprise of a hole in the lower face of the perforated surfaces  116   118   120   122  and a plurality of sloped surfaces  1004  that are declined from a top face of the perforated surface toward the hole  1002  located at the bottom face of the perforated surfaces  116   118   120   122 . In some embodiments such as  FIGS. 10 a , 10 b  and 10 c -10 f   , the surfaces  1004  can be planar. However, in alternate embodiments such as  FIG. 10 c   , the surface can be curved  1006 . Moreover, in some embodiments, such as those depicted in  FIGS. 10 g -10 i   , the hole  1002  can be substantially orthogonal to the plane of the perforated surfaces  116   118   120   122 . Additionally, it should be well understood by those of ordinary skill in the art that the presented apertures  1000 , holes  1002 , surfaces  1004 , curves,  1006  are illustrative only any can have any known, convenient and/or desired geometric configurations. Moreover, it should be well understood by those of ordinary skill in the art that while a single perforated surface  116   118   120   122  can be designed to allow passage of modular building blocks less than a specified dimension to pass through it, the apertures  1000  in either each of or within the individual perforated surfaces need not be the same or identical. Thus, a single perforates surface, for example  122  can comprise multiple different apertures  1000  and/or in some embodiments can comprise apertures  1000  of a single type/style. 
       FIG. 11  depicts a method  1100  of sorting modular building blocks. In step  1102  a plurality of perforated surfaces  116   118   120   122  are provided or obtained, each of the perforated surfaces  116   118   120   122  being adapted and configured to allow block having less than a specified dimension to pass through the apertures  1000  in the perforated surfaces  116   118   120   122 . 
     In step  1104  a housing  102  adapted and configured to support the plurality of perforated surfaces  116   118   120   122  is provided or obtained. Then in step  1006 , at least one of the perforated surfaces  116   118   120   122  is coupled with the housing  102 . In some embodiments in which a plurality of perforated surfaces  116   118   120   122  are coupled with the housing  102 , the perforated surfaces  116   118   120   122  can be coupled with the housing  102  such that the size of the apertures  1000  increase with the distance from the base  126  of the housing  102 . 
     In step  1008  the modular building blocks are introduced onto the at least one perforated surface coupled with the housing  102  and then in step  1110 , the housing. The base  126  of the housing  102  comprises one or more discontinuities  206  such that as the base is agitated in step  1110 , a vertical component of acceleration is introduced into the system in step  1112  as the base  126  transitions across the discontinuities  206  with the base  126  is in contact with a surface upon which it is resting. Then in step  1114  modular building blocks can pass through the at least one perforated surface toward the base  126  based at least in part on the vertical component of acceleration from step  1112 . 
     Although exemplary embodiments of the invention have been described in detail and in language specific to structural features and/or methodological acts above, it is to be understood that those skilled in the art will readily appreciate that many additional modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the invention. Moreover, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Accordingly, these and all such modifications are intended to be included within the scope of this invention construed in breadth and scope in accordance with the appended claims.