Patent Publication Number: US-2013244530-A1

Title: Foam construction toy

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/612,722, filed on Mar. 19, 2012. The subject matter of the earlier filed Provisional Patent Application is incorporated herein by its entirety. 
    
    
     FIELD 
     The present invention generally relates to a toy, and more particularly, to a construction toy using structural elements connected by reconfigurable nodes. 
     BACKGROUND 
     Currently, there are construction toys that allow a user, such as a child. to build structures using structural components. However, these components are generally not flexible in nature, and may be limited in design capabilities. 
     SUMMARY 
     Certain embodiments of the present invention may provide solutions to the problems and needs in the art that have not yet been fully identified, appreciated, or solved by current construction toys. For example, a construction toy in some embodiments may utilize a plurality of nodes, studs, and structural elements to construct a toy or an object. 
     In one embodiment, an apparatus is provided. The apparatus includes at least one node having a plurality of holes, and at least one structural element that is configured to connect to the at least one node. At least one stud is used to connect the at least one structural element with the at least one node. 
     In another embodiment, an apparatus is provided. The apparatus includes a plurality of structural elements. Each of the plurality of structural elements are configured to connect to each other using a node-stud assembly or a connector unit. The node-stud assembly comprises a node having a plurality of holes and a stud configured to connect a structural element with the node. The connector unit configured to connect a first structural element with a second structural element. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of certain embodiments of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. While it should be understood that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1A  illustrates a foam construction toy forming a shape of a cube, according to an embodiment of the present invention. 
         FIG. 1B  illustrates a foam construction toy forming a shape of a house, according to an embodiment of the present invention. 
         FIG. 1C  illustrates a foam construction toy forming a shape of a ship, according to an embodiment of the present invention. 
         FIG. 1D  illustrates a foam construction toy forming a shape of a tunnel, according to an embodiment of the present invention. 
         FIG. 1E  illustrates a foam construction toy forming a shape of a rectangle with a cover, according to an embodiment of the present invention. 
         FIG. 2  illustrates a node-stud assembly, according to an embodiment of the present invention. 
         FIG. 3A  illustrates a foam member attachment system, according to an embodiment of the present invention. 
         FIG. 3B  illustrates a foam member attachment system having a partial stiffening tube, according to an embodiment of the present invention. 
         FIG. 3C  illustrates a foam member attachment system having a stiffening stud, according to an embodiment of the present invention. 
         FIG. 4A  illustrates a lawn anchor with a stud, according to an embodiment of the present invention. 
         FIG. 4B  illustrates a lawn anchor with an interface, according to an embodiment of the present invention. 
         FIG. 4C  illustrates a lawn anchor with a stud and an interface, according to an embodiment of the present invention. 
         FIG. 4D  illustrates a lawn anchor with an adapter and node, according to an embodiment of the present invention. 
         FIG. 5  illustrates an application of a lawn anchor assembly, according to an embodiment of the present invention. 
         FIG. 6  illustrates a cross sectional view of a stud, according to an embodiment of the present invention. 
         FIG. 7  illustrates a stud with grooves, according to an embodiment of the present invention. 
         FIG. 8A-C  illustrates multiple views of a stud with tabs, according to an embodiment of the present invention. 
         FIGS. 9A and 9B  illustrate a top view and a front view of a foam member attachment system using first and second sets of locking mechanisms, according to an embodiment of the present invention. 
         FIGS. 10A and 10B  illustrate a top view and a front view of a stud, according to an embodiment of the present invention. 
         FIG. 11  illustrates a connector assembly, according to an embodiment of the present invention. 
         FIGS. 12A and 12B  illustrate a top view and a front view of a two-piece connector assembly, according to an embodiment of the present invention. 
         FIG. 13  illustrates a connector assembly system, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Embodiments of the present invention pertain to a construction toy  100  using, for example, foam members  106  for structural members connected by reconfigurable nodes. See, for example,  FIGS. 1A-1D . In one embodiment, a pool noodle is a typical example of a foam member  106 . While this application discusses the use of foam elements, a person of ordinary skill in the art will readily appreciate that any suitable structural element may be used to construct the toy. For example, foam members  106  may be composed wood, plastic material, etc. Foam members  106  may be connected to one another via a node  102 . A stud  104  is used to connect foam member  106  to node  102 . This allows construction of a wide variety of projects, shapes, and configurations. 
     Some projects can be used for practical purposes, and others may be used simply for artistic purposes. The need fulfilled by this construction toy in some embodiments is to provide a fun and educational experience for children, and possibly adults. This construction toy may help children to visualize three-dimensional structures with a practical aspect not normally found in other toys. For instance, the construction toy can be configured into a soccer goal, a playhouse, a lemonade stand, a volleyball net, and many more items. 
     For example, construction toy  100  may be configured to form a cube (see  FIG. 1A ), a house (see  FIG. 1B ), a ship (see  FIG. 1C ), a tunnel (see  FIG. 1D ), or any shape that would be readily appreciated by a person of ordinary skill in the art. In  FIG. 1E , for example, construction toy  100  may include a hook  108 , allowing a string  110  to wrap around hook  108 , such that a panel  112  may be affixed to a side of construction toy  100 . 
     The embodiments of the present invention may utilize reconfigurable joints, use the elastic properties of the foam to accomplish the connections, and the system as a whole may allow many different outcomes. As shown in  FIGS. 1A-1E , construction toy  100  may include nodes  102 , studs  104 , foam members  106 , and panels  112 . 
       FIG. 2  illustrates a node-stud assembly  200 , according to an embodiment of the present invention. In this embodiment, node-stud assembly  200  includes a node  202  and a stud  206 . 
     In certain embodiments, node  202  may be a rectangular element, a triangular element, or any shape or design that would be readily appreciated by a person of ordinary skill in the art. Node  202  may be composed of plastic material, wood, etc., and may include a plurality of holes  204  to allow reception of stud  206 . It should be appreciated that each of the plurality of holes  204  may include grooves (not shown) to allow stud  206  to screw on. 
     Stud  206  may include an attachment unit  208 , such as a threaded interface to operably connect with node ball  202 . Collar  210  acts as a stopper to prevent a foam member (see  FIG. 3A ) from moving closer to node  202  when connecting node  202  to the foam member. A bearing ring  214  may also be utilized to stabilize node ball  202  when node  202  is attached to stud  206 . 
     Located between bearing ring  214  and collar  210  is a recessed groove  216 . Recessed groove  216  allows a panel, or other accessories, to be attached to the construction toy. This may be an alternative embodiment to that shown in  FIG. 1E . Further, an elongated portion  212  of stud  206  may be inserted into the foam member. See, for example,  FIG. 3A . 
       FIG. 3A  illustrates a foam member attachment system  300 , according to an embodiment of the present invention. In this embodiment, a node  302  is connected to a stud  304  to form a node-stud unit. The node-stud unit may be inserted into a foam member  306 . When the node-stud unit is inserted into foam member  306 , the connection between stud  304  and foam member  306  utilizes friction to secure stud  304  within a hollow section  308  of foam member  306 . 
     It should be appreciated that foam member  306  includes a taper  310  to allow for a larger, more compact surface area, and to allow additional foam members to connect to node  302 . For example,  FIG. 3C  shows a plurality of foam members  306  connected to node  302  in a more compact manner. 
     Because foam members  306  may vary in size, the structural integrity may be compromised for foam members  306  that are larger than a certain size, depending on the material. To resolve this issue, hollow section  308  may include a partial stiffening tube  312  to prevent foam member  306  from bending, providing structural integrity. See, for example,  FIG. 3B . Stiffening tube  312  may have a stiffness configured to increase or decrease the amount of stiffness in foam member  306 . This may be applied to longer foam members. 
     In other embodiments, to increase the stiffness throughout foam member  306 , hollow section  308  may include a stiffening tube  312  throughout. See  FIG. 3C , for example. This allows for more rigidity at the ends of foam member  306 . Because a stiffening tube  312  is placed throughout hollow section  308 , stud  304  may slide in and out of foam member  306 , potentially compromising the construction toy. To prevent stud  304  from sliding, a gripping member  314  may be utilized. Gripping member  314  may be composed of material such as foam, vinyl, rubber, etc. This allows stud  304  to maintain position within hollow section  308  of foam member  306  unless stud  304  is removed by a user. 
       FIG. 4A  illustrates a lawn anchor  400  with a stud  406 , according to an embodiment of the present invention. In this embodiment, lawn anchor  400  includes a stake  402  configured to be inserted into the lawn, sand, or other suitable medium. A collar  404  is utilized to prevent a foam member, when attached to stud  406 , from moving forward. See, for example, the description related to  FIG. 5  below. 
     In certain embodiments, such as that shown in  FIG. 4B , lawn anchor  400  may include an interface  408  to allow a stud  406  to be attached to lawn anchor  400 . This allows for the lawn anchor assembly to be completely assembled as a single unit. See, for example,  FIG. 4C . Other embodiments, such as that shown in  FIG. 4D , may include an adapter  410  that can be situated between interface  408  and node  412 . Stated differently, adapter  410  allows a node  412  to connect with interface  406  to complete the lawn anchor assembly. 
       FIG. 5  illustrates an application of a lawn anchor assembly  500 , according to an embodiment of the present invention. Lawn anchor assembly  500 , in this embodiment, includes two stakes  502  at each end of foam member  510  forming, for example, a tunnel. Collar  504  allows stake  502  to be inserted a predefined distance into lawn  520 . Also attached to stake  502  is a stud  506  similar to that shown in  FIG. 4C . Stud  506  may be inserted into a hollow section  512  of foam member  510 . 
       FIG. 6  illustrates a cross sectional view of a stud  600 , according to an embodiment of the present invention. Stud  600  may include a threaded interface  602  to allow stud  600  to screw on, and securely attach to, a node. Contact surface  604  is configured to secure the seating of stud  600  on the receiving surface of the node. Recessed groove  606  may allow a panel, or other accessories, to be attached to stud  600 . A collar  608 , as discussed above, may be utilized to act as an axial stop when a foam member is attached to elongated portion  610 . Elongated portion  610  of stud  600  may include a contact surface providing sufficient frictional holding force when inserted into the hollow portion of the foam member. 
       FIG. 7  illustrates a stud  700  with grooves  704 , according to an embodiment of the present invention. Because the design described herein relies primarily on friction to hold stud  700  and a foam member together, the air pressure within the foam member can affect the holding force. The air pressure, however, can also hinder the insertion of stud  700  into the foam member. To reduce some of the air pressure upon insertion and still retain this holding force, a plurality of grooves  704  can be placed on an elongated portion  702  of stud  700 . 
       FIGS. 8A-C  illustrate multiple views of a stud  800  with tabs  802 , according to an embodiment of the present invention. In this embodiment, stud  800  includes tabs  802  to allow stud  800  to be removed from a foam member in an efficient manner when pressed by the user. 
     Fish bones  806  are located on the inner side of elongated member  804 , creating air pockets  808  between fish bones  806 . Air pockets  808  allow each fish bone  806  to act as a spring, enabling elongated member  804  to easily slide into the foam member. Essentially, as elongated member  804  slides into the foam member, each fish bone  806  is compressed between elongated member  804  and central spine  808 . Once elongated member  804  is inserted into the foam member, each fish bone  806  is configured to retract into position, causing elongated member  804  to firmly press against the inner walls of the foam member. This allows the holding force to be maintained in an axial direction. 
     It should be appreciated that in certain embodiments, the outer surface of elongated member  804  may have a textured surface configured to secure stud  800  within the foam member. This prevents stud  800  from falling out of the foam member and improves the integrity of the construction toy. 
       FIGS. 9A and 9B  illustrate a top view and front view of a foam member attachment system  900  using a first set of locking mechanisms  908  and a second set of locking mechanisms  916 , according to an embodiment of the present invention. In this embodiment, a node  902  having a plurality of holes  904  may be connected to a foam member  918  via a stud. Each component of the stud is described in more detail in  FIG. 10 . 
     A hollow portion  920  of foam member  918  includes a solid surface  922  with an annular groove  924  near the opening of foam member  918 . Annular groove  924  in this embodiment allows flexibility when constructing the toy. When elongated portion  914  of the stud is inserted in hollow portion  920  of foam member  918 , a second set of locking mechanisms (e.g. stud locking mechanism)  916  slide into annular groove  924  to stabilize, and prevent movement of, elongated portion  914  of the stud within foam member  918 . 
     In order to remove the stud from foam member  918 , a second set of tabs  912 B is utilized. For example, when a user applies pressure to second set of tabs  912 B, second set of locking mechanisms  916  is configured to slide out of annular groove  924  to allow the stud to be removed from foam member  918 . 
     Also, in order to secure the stud within node  902 , the stud may include a first set of locking mechanisms  908  to prevent node  902  from detaching from the stud. However, in order to release the stud from node  902 , a first set of tabs  912 A is utilized. For instance, when a user applies pressure or force to first set of tabs  912 A, first set of locking mechanisms  908  is configured to compress, allowing the stud to be removed from a hole of node  902 . It should also be appreciated that first set of locking mechanisms  908  do not touch, and may be proximate to collar  910 . See  FIG. 10  below for a more detailed description of the stud. 
       FIGS. 10A and 10B  illustrate a top view and front view of a stud  1000 , according to an embodiment of the present invention. Stud  1000  may be made of three separate components, i.e., a first clip attachment  1002  to secure stud  1000  to a node, a second stud attachment  1008  to secure stud  1000  to a foam member, and an internally threaded collar (e.g., a nut)  1016  to secure stud  1000  to the node. 
     First clip attachment  1002  in this embodiment includes a first set of locking mechanisms  1004  and a first set of tabs  1006 . As discussed above, first set of locking mechanisms  1004  is configured to secure stud  1000  against the node. Further, when the user applies pressure to first set of tabs  1006 , first set of locking mechanisms  1004  is configured to compress, allowing stud  1000  to be removed from the node. 
     Second clip attachment  1008  in this embodiment includes a second set of locking mechanisms  1010 , a second set of tabs  1012 , and a threaded section  1014 . Similar to  FIGS. 9A and 9B , second set of locking mechanisms  1010  are configured to secure second clip attachment  1008  within a hollow section of the foam member. When the user applies pressure to second set of tabs  1012 , second set of locking mechanisms  1010  is configured to release second clip attachment  1008  from the hollow section of the foam member. Threaded section  1014  is configured to securely connect first clip attachment  1002  and second clip attachment  1008  to collar  1016  to form stud  1000 . 
       FIG. 11  illustrates a connector assembly  1100 , according to an embodiment of the present invention. Connector assembly (or connector unit)  1100  includes two studs—a first stud  1102 A and a second stud  1102 B, and a collar  1104 . This allows two foam members to connect to each other via connector assembly  1100  to extend the length of the foam members. In certain embodiments, multiple connector assemblies may be used to extend the foam members. Because the foam members may be configured to float in water, this connector assembly may be particularly useful in a pool, where a plurality of foam members may be connected together and used as lane markers. 
       FIGS. 12A and 12B  illustrate a top view and a front view of a two-piece connector assembly  1200 , according to an embodiment of the present invention. In this embodiment, two-piece connector assembly  1200  includes a first stud  1202  and a second stud  1208 , each stud  1202 ,  1208  is configured to be inserted into a foam member. First stud  1202  may include a first set of tabs  1204  and a first set of locking mechanisms  1206 , and second stud  1208  may include a second set of tabs  1210  and a second set of locking mechanisms  1212 . 
       FIG. 13  illustrates a connector assembly system  1300 , according to an embodiment of the present invention. In this embodiment, two foam members  1302 ,  1308  are connected to each other via a two-piece connector assembly. The connector assembly includes a first stud  1320  and a second stud  1330 . First stud  1320  is connected to first foam member  1302  and second stud  1330  is connected to second foam member  1310 . 
     In order to secure first stud  1320  and second stud  1330  within hollow portions  1304 ,  1312  of foam members  1302 ,  1310 , respectively, locking mechanisms  1324 ,  1334  are configured to slide into annular grooves  1308 ,  1316  when first stud  1320  and second stud  1330  are inserted into foam members  1302 ,  1310 , respectively. To release first stud  1320  and second stud  1330 , tabs  1322 ,  1332  may be pressed, causing locking mechanisms  1324 ,  1334  to slide out of annular grooves  1308 ,  1316 . 
     One or more embodiments of the present invention pertain to a foam construction toy. The foam construction toy may include at least one node and a plurality of foam members configured to connect with the at least one node to form a structural element. A stud may be used to connect each of the plurality of foam members to the at least one node. 
     It will be readily understood that the components of the invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the detailed description of the embodiments is not intended to limit the scope of the invention, but is merely representative of selected embodiments of the invention. 
     The features, structures, or characteristics of the invention described throughout this specification may be combined in any suitable manner in one or more embodiments. For example, the usage of “certain embodiments,” “some embodiments,” or other similar language, throughout this specification refers to the fact that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. Thus, appearances of the phrases “in certain embodiments,” “in some embodiments,” “in other embodiments,” or other similar language, throughout this specification do not necessarily all refer to the same embodiment or group of embodiments, and the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     One having ordinary skill in the art will readily understand that the invention as discussed above may be practiced with steps in a different order, and/or with hardware elements in configurations that are different than those which are disclosed. Therefore, although the invention has been described based upon these preferred embodiments, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions would be apparent, while remaining within the spirit and scope of the invention.