Patent Publication Number: US-2020282322-A1

Title: Construction Toy Playset with Foam Noodles and Angled Miter

Description:
RELATED APPLICATIONS 
     The present application is a Continuation in Part of U.S. application Ser. No. 16/664,891 filed on Oct. 27, 2019 that is a Continuation in Part of U.S. application Ser. No. 15/951,199 filed on Apr. 12, 2018 that is a Continuation in Part of U.S. application Ser. No. 15/344,333 filed Nov. 4, 2016 that claims benefit under 35 U.S.C. 119(e) of U.S. Provisional Applications 62/251,039 filed on Nov. 4, 2015, the disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF TECHNOLOGY 
     Typically, construction toys for children are blocks made of wood and or hard plastic. While playing with construction toys is often an immersive experience, few construction toys allow for the building of structures that are full size playsets that children can be inside safely. 
     SUMMARY OF DESCRIBED SUBJECT MATTER 
     In one objective of the current disclosed technology, miter device having miter base comprising: a bottom support comprising a top planar surface, a first end, a second end, a first lateral section and a second lateral section; a first ridge protrusion along the first lateral section and the first ridge protrusion extending above the top planar surface of the bottom support; a second ridge protrusion along the second lateral section and the second ridge protrusion extending above the top planar surface of the bottom support. The miter device further comprising at least one U-shaped miter guide and the U-shaped miter guide comprising; a first miter guide end and a second miter guide end; the first miter guide end is pivotably attached to the first ridge protrusion; and the second miter guide end is pivotably attached to the second ridge protrusion. Wherein the U-shaped miter guide arches over the miter base and the U-shaped guide is operable to move in a plane between 0 to 90 degrees in relation to the miter base. 
     In another objective of the current disclosure there is a miter device comprising a miter base comprising: a bottom support comprising a top planar surface, a first end, a second end, a first lateral section and a second lateral section; a first ridge protrusion along the first lateral section and the first ridge protrusion extending above the top planar surface of the bottom support; a second ridge protrusion along the second lateral section and the second ridge protrusion extending above the top planar surface of the bottom support. The miter device further comprising an interference lock pivotally connected to the second ridge protrusion. The miter device also comprising at least two U-shaped miter guides and each U-shaped miter guide comprising: a first miter guide end and a second miter guide end; the first miter guide end is pivotably attached to the first ridge protrusion and the first miter guide end further comprising protrusion gears; and the second miter guide end is pivotably attached to the second ridge protrusion and the second miter guide end further comprising protrusion gears. Wherein the U-shaped miter guide arches over the miter base and the U-shaped guide is operable to move in a plane between 0 to 90 degrees in relation to the miter base. 
     Wherein the U-shaped miter guides, the first ridge protrusion, the planar surface and the second ridge protrusion defines a tunnel for placement of a log under the U-shaped guides, on the planar surface and between the first ridge protrusion and the second ridge protrusion. Wherein the protrusion gears of a first miter guide and the protrusion gears of a second miter guide are configured to adjustably interconnect the two miter guides. Wherein the interference lock is configured to pivot and lock the protrusion gears in a fixed position to maintain at least two miter guides in a predetermined position. 
     In yet another objective of the current disclosure, a miter device is described having a miter base and the miter base comprises: a bottom support comprising a top planar surface, a first end, a second end, a first lateral section and a second lateral section; a first ridge protrusion along the first lateral section and the first ridge protrusion extending above the top planar surface of the bottom support; a second ridge protrusion along the second lateral section and the second ridge protrusion extending above the top planar surface of the bottom support; a set of channels comprising a first channel in an outer portion of the first ridge protrusion and a second channel in an outer portion of the second ridge protrusion. 
     The miter device further comprising a plurality of V-sections that are configured to form a V-section array comprising: a plurality of combination guides each having a combination guide first end and a combination guide second end; a plurality of top connectors each having a top connector first end and a top connector second end; two parallel first combination guides of the plurality of combination guides positioned at either lateral side of the miter base; two parallel sets of middle combination guides of the plurality of combination guides positioned at either lateral side of the miter base; and two parallel last combination guides of the plurality of combination guides positioned at either lateral side of the miter base. Wherein the two parallel first combination guides and the two parallel last combination guides are pivotally attached at the combination guides first ends to the miter base; and pivotally attached at the combination guide second end to a second end of an additional combination guide of the set of middle combination guides and a top connector. Wherein the two parallel sets of middle combination guides are pivotally attached at each of the combination guides first ends to the miter base and to a first end of an additional combination guide of the set of combination guides. Wherein the two parallel sets of middle combination guides are pivotally attached at each of the combination guides second ends to a second end of an additional combination guide of the set of middle combination guides and a top connector. 
     Further, wherein the plurality of top connectors is configured to support combination guides that are parallel to each other on each lateral side of the miter base. The plurality of top connectors is configured to bridge over the miter base and the V-sections are operable to move in a plane between 0 to 90 degrees in relation to the miter base. The miter device also comprising: a plurality of pivot pins and each pivot pin having a first pivot pin end and a second pivot pin end and the first pivot pin end configured to move laterally in at least one of the set of channels; and a subset plurality pivot pins are lockable pivot pins configured to lock in a predetermined position in at least one of the set of channels. Wherein the V-section array is maintained in a predetermined position and maintains the angles in relation to the miter base in a predetermined position. 
     In another objective of the current disclosure is a method of using the miter for cutting and removing a wedge from a log of a toy building set comprising:
         a. selecting the log;   b. determining the angle to cut in the log resulting in a determined angle, wherein the wedge is removable from the log;   c. placing the miter device on a flat surface;   d. pivoting the at least one U-shaped meter guide to the determined angle;   e. placing the log in the tunnel of the miter device;   f. placing a toy saw adjacent to the at least one U-shaped meter guide;   g. sawing a first angled cut in the log;   h. repeating processes a to f;   i. sawing a second angled cut in the log creating a wedge;   j. removing the wedge from the log;   k. removing the log from the miter device.       

     In a final objective of the disclosed technology there is a method of using the construction playset to take a straight log and create a curved log comprising the following steps: selecting a log and determining the length and/or angled cut of the log needed; placing an angled miter on a flat surface and positioning guides on the angled miter to desirable angles. Subsequently, the log is placed in the angled miter and the miter guides are correctly positioned for a saw to cut and remove an angled wedge out of the log, so the log will bend to the same angle as the angled wedge that was removed. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Some embodiments of the invention are described herein with reference to the accompanying figures. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ one or more illustrative embodiments: 
         FIG. 1  illustrates a perspective view of an angled miter and a log with a wedge shape cut and removed from the log in accordance with the current disclosure; 
         FIG. 2  illustrates a perspective view of an angled miter and a log with multiple angled wedge shapes cut and removed from the log in accordance with the current disclosure; 
         FIG. 3  illustrates a perspective assembly view of an angled miter of the current disclosure; 
         FIG. 4  illustrates a side view of the angled miter of  FIG. 3 ; 
         FIG. 5  illustrates a front view of the angled miter of  FIG. 3 ; 
         FIG. 6  illustrates a top view of the angled miter of  FIG. 3 ; 
         FIG. 7  illustrates a bottom view of the angled miter of  FIG. 3 ; 
         FIG. 8  illustrates a perspective view of an angled miter in accordance with the current disclosure; 
         FIG. 9  illustrates a perspective view of an angled miter in accordance with the current disclosure; 
         FIG. 10  illustrates a perspective view of the angled miter of  FIG. 9  in a different configuration and in accordance with the current disclosure; and 
         FIG. 11  shows a perspective view of an angled miter in accordance with the current disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various detailed embodiments of the present disclosure, taken in conjunction with the accompanying figures, are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative. In addition, each of the examples given in connection with the various embodiments of the present disclosure is intended to be illustrative, and not restrictive. 
     Throughout the specification, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “in one embodiment” and “in. some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. Thus, as described below, various embodiments may be readily combined, without departing from the scope or spirit of the present disclosure. 
     The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” “an,” “the” include plural references. The meaning of “in” includes “in” and “on.” 
     To aid in describing the present disclosure, directional terms may be used in the specification and claims to describe portions of the current disclosure (e.g., upper, lower, left, right, etc.). These directional definitions are merely intended to assist in describing and claiming the current disclosure and are not intended to limit the current disclosure in any way. In addition, reference numerals that are introduced in the specification in association with a figure may be repeated in one or more subsequent figures without additional description in the specification, in order to provide context for other features. 
     As used herein, the term “plurality” means more than one. 
     As used herein, the terms “noodle”, “log” and “block” are used interchangeably. 
     The term “substantially flat planar surface”, as used herein, is defined as a flat section along the length of the side of a log and from 25 percent to 100 percent of the width of a side of the log. 
     The term “fixed” connection, as used herein, is defined as one which is expected to, or does cause damage to, one of the parts described when removed. 
     The term “removable”, as used herein, is defined as able to connect and disconnect repeatedly (&gt;6 times) without causing damage to a connector piece or parts being connected. 
     The terms “pivoted”, “pivotably connected”, “pivotably attached” as used herein are defined as a linkage that allows at least one degree of freedom of movement similar to a hinge between connected logs or parts. 
     The terms “adjustable” and “adjustably”, as used herein, are defined as able to be changed to suit particular needs. 
     The disclosed technology relates to a building system for children that allows them to construct structures and playsets from hollow foam extrusions or foam logs that are stackable so they can make playsets of their own design or existing designs in which they can hide, play and let their imaginations soar. According to some embodiments, a log is a blown or expanded hollow circular extrusion of plastic. In some embodiments, the log is an elongated hollow cylinder with flattened exterior planar sections or substantially flat planar surfaces. 
     In some embodiments, the substantially flat planar surfaces are opposite one another. In some embodiments, the logs comprise apertures on two planar surfaces and at least one curved surface. In some embodiments the log comprises apertures at a minimum on the planar surfaces. These logs, in some embodiments, are straight, but by cutting and removing wedge shaped pieces from a log, the log can be easily bent into a predictable angle or curve. In some embodiments, the log is bilaterally symmetrical with two curved surfaces and two planar surfaces. In some embodiments the two flat surfaces have a hinge detail. 
     In some embodiments, an angled miter guide is used to cut two defined angled saw cuts to form a wedge in a log and then the wedge is removed from the log. In some embodiments, the removed wedge creates a wedge-shaped aperture which allows the log to bend to the same defined angle of the removed wedge. In some embodiments, the logs are bent into curves which allows for construction of toy playsets to be used in the building of a bow of a ship, a tower in a castle, or similar items. 
     In some embodiments, the construction toy playset may include injection molded fasteners. In some embodiments, the apertures of the log are configured for insertion of one end of the injection molded fasteners. In some embodiments, a string is passed through a portal of the injection molded fastener that protrudes from an outer surface of the log and the string is pulled tight such that the string and injection molded fasteners maintain the log in a predetermined, desired curved position. In some embodiments, adhesives, such as, but not limited to, hot melt, adhesive tape, packing tape or any combination thereof, maintain the log in the predetermined desired curved position. In some embodiments, removing multiple wedge shapes allows angles, curves and even full circles resembling a wheel to be formed with an originally straight log. 
     With reference now to the drawings, an exemplary angles miter device  30  is shown for cutting wedges at predetermined angle in a log of an exemplary construction toy playset.  FIGS. 1 and 2  schematically illustrates the exemplary angled miter device  30  (hereinafter miter). In some embodiments, the exemplary miter  30  comprises at least two miter guides  31 , a miter base  33  and guide supports  32 . In some embodiments, the miter base  33  is configured to support a log  10  in position for cutting. In some embodiments, each miter guide  31  is U-shaped comprising two ends further comprising a first guide end and a second guide end. In some embodiments, the ends of each of the U-shaped guide are configured to be rotatably attached and adjacent to the miter base  33 , and each U-shaped guide arches over the miter base, thus making each U-shaped guide operable to move in a plane between 0 to 90 degrees in relation to the miter base. In some embodiments, a log  10  of the exemplary construction toy playset is placed on the miter base  33  with the, at least two, miter guides  31  positioned such that toy saw blade  20  will cut the log at predetermined angles. 
     In some embodiments, each miter guide  31  guides a toy saw blade  20  such that the cuts converge from opposing directions assisted by the miter guides. Thus, the cuts of opposing direction form a wedge-shaped piece  15  configured to be removed from the log  10  creating a wedge-shaped aperture  15   a . In some embodiments, the miter guides  31  are maintained in a predetermined position by guide supports  32 . In some embodiments, an exemplary miter is made of plastic, metal, or any combination thereof. 
     Now onto  FIG. 3 , which illustrates that in some embodiments, support guides  32  are configured to be pivotally attached to the miter guides. The support guides may be held in predetermined positions by design grooves  34  on the miter base  33 , thus supporting the miter guide in a predetermined position. The design grooves  34  used for support guides  32  may be for example, and not limited to, detents, channels, interference designs or any combination thereof. In some embodiments, the support guides maintain the angle of the meter guides by for example, and not limited to using, indents in the base operable to hold removable pegs, indents in the operable to hold fixed pegs, indents in the base to receive snaps, any method of pivoting, rotating, or sliding protrusions to anchor a miter guide to temporarily fix its position, or any combination thereof.  FIGS. 4 through 7  are illustrations of different views for  FIG. 3 . In some embodiments, the guide supports each having a first guide support end and a second guide support end with the first guide support end configured to removably engage with a plurality of design grooves (not shown) in the miter guide and the second guide support end pivotably attached to the miter base (not shown) to maintain the at least one miter guide in a predetermined position. 
       FIG. 11  illustrates an exemplary miter  30 , that in some embodiments is similar to the exemplary miter of  FIG. 3 . In some embodiments, the exemplary miter of  FIG. 11  comprises support guides  32  that are configured, at a second end, to be pivotably attached to the miter base  33 . In some embodiments, detail part  46  is configured to pivotally attach two parallel support guides to miter base  33 . In some embodiments, the support guides further comprise a knob  47  extending from a first end of support guides  32 . In some embodiments, the knob may be held in predetermined positions on miter guide  31  by engaging in one of a plurality of guide apertures  45  on the miter guide  31 , thus supporting the miter guide in a predetermined position. In some embodiments, the knob and guide apertures may be any protrusion on a support guide and any aperture configured to receive that protrusion on the miter guide. 
       FIG. 8  illustrates an exemplary miter  30  of the current disclosure. In some embodiments, the ends of the miter guides  31  are pivotably connected to the miter base and further the ends of the miter guides comprise protrusion gears  34   a  that adjustably interconnect the two miter guides. In some embodiments, interference lock  32   a  is pivotably connected to the miter base and may be configured to lock the miter guides at a predetermined position by pivoting interference lock  32   a  to engage and stop the protrusion gears  34   a  from rotating. In some embodiments, cam locks are used to stop the protrusion gears  34   a  from rotating. 
       FIGS. 9 and 10 , illustrate an exemplary miter  30 , with a miter base  33  that comprises two channels  36  and each channel is on each of two lateral sides of the miter base. In some embodiments, the exemplary miter comprises a plurality of V-sections configured to form a V-section array  43  that comprises combination guides  31   a  and top connectors  41 . The combination guides  31   a  are configured to both support another combination guide and be a guide for a saw thus providing both functions of  31  and  32  in  FIG. 3 . 
     In some embodiments, channels  36  receive one end of a plurality of pivot pins  35 ,  35   a , and  38  that are configured to pivotably connect one combination guide to the miter base and/or two combination guides to each other and the miter base. In some embodiments, the pivot pins may be, but are not limited to plastic, metal, or any combination thereof. In some embodiments, the pivot pins are further configured to move laterally in channels  36 . In some embodiments, each combination guide  31   a  is also pivotably attached with pivot pins to another combination guide and top connectors  41  and top connectors  41  are configured to support combination guides  31   a  that are parallel to each other on each lateral side of the miter base  33 . In some embodiments, lockable pivot pins  35   a  and  38  lock the pivot pins at predetermined positions in the channel  36  and therefore maintain the V-section array in a predetermined position maintaining the angles in relation to the miter base  33 . Thus, the V-section array is configured to be adjustable to desired predetermined angles in relation to the miter base  33 . In some embodiments, the exemplary miter of  FIGS. 9 and 10  further comprises raised indicators  49  configured to support guided placement of pivot pins  35 ,  35   a  and  38  in the channel. 
     In some embodiments, the exemplary construction toy playset, reduces the amount of plastic needed to build a conventional playset by 75 to 90 percent. In some embodiment, the exemplary construction toy playset reduces the amount of plastic needed to build a conventional playset by 85 percent. Using less plastic than conventional playsets is environmentally friendly. In some embodiments, all of the logs, fasteners, saws and miters are totally recyclable. In some embodiments, the construction toy playsets allow for inside, outside and water-play. In some embodiments, the construction toy playset withstands rain, wind and intense sunlight to the same degree as existing rotomolded conventional playsets because the logs are also made of the same polyethylene material that is used in the conventional rotomolded playset products. In some embodiments the construction toy playset allows users (children) to build their own designs with a soft material that can be cut, bent and fastened together to create a wide range of entertaining playsets. These playsets provide children not only excitement during the construction phase, but also a durable, imaginative educational toy to engage with after construction. 
     While the disclosed technology has been taught with specific reference to the above embodiments, a person having ordinary skill in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the disclosed technology. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Combinations of any of the methods, systems, and devices described herein are also contemplated and within the scope of the disclosed technology.