Patent Publication Number: US-9839860-B2

Title: Interlocking construction toy

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. provisional patent application No. 62/159,967, filed on May 12, 2015, which is hereby incorporated in its entirety by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to interlocking construction toys. 
     BACKGROUND OF THE INVENTION 
     Toy construction blocks have been popular for many years. The advent and advancement of injection molding plastics technology have resulted in the development of construction block sets such as LEGO (commercially available from the Lego Group), K&#39;NEX (commercially available from K&#39;NEX) and Clics (commercially available from Clics Toys). Each one of these sets has its own unique characteristics such as the geometrical shape of the blocks, the method of connection, the degree of structural stability etc. These unique characteristics introduce particular features of the blocks. For example, in the case of the basic LEGO block sets, two block elements can connect to each other in one direction only (one above the other), or in the case of the Clics blocks, two block elements can connect to each other side-by-side with a 0-90 degree rotation about their common edge. Generally, the block elements of these sets connect to each other without the need for a connecting pin to bring the two elements together. The connection is usually accomplished by incorporating inter-connecting male and female features into the design of each block. There are blocks however, which also use connecting elements. 
     There are other forms of construction blocks on the market, such as Kapla (commercially available from Kapla Toys), whose blocks are typically larger than those of LEGO etc. which provide the ability to create large structures. Since there is no connection ability between such blocks, the structures created are unstable. 
     Richard Onanian has created a block and peg combination which is described in the following patents: U.S. Pat. No. 3,205,611; U.S. Pat. No. 3,195,266; U.S. Pat. No. 3,545,122; U.S. Pat. No. 2,885,822 and U.S. Pat. No. 2,769,428. 
     Other block and peg toys are described in the following publications: US2006276100, DE202004009465U, WO10012050A, KR20100068945, US2009017716A, JP2008212230A, US2008075528A, WO07120071A, US2007130874A, US2008214087A, KR200257670, KR20100068945A, WO10012050A, US2009017716A, WO08078942A, US2008075528A, WO07120071A, WO07021090A, US2008214087A, WO04067128A, US2008207082A and KR200257670Y. They are also described in the patents: U.S. Pat. No. 6,736,691, U.S. Pat. No. 5,924,906A, U.S. Pat. No. 5,788,555A, GB 2108857A, U.S. Pat. No. 3,613,291A, EP 0911070A, BE 1010737A, U.S. Pat. No. 5,009,599A, FR 2382254A, GB1238975A, U.S. Pat. No. 3,585,752, U.S. Pat. No. 3,496,670, U.S. Pat. No. 3,611,609, P 0911070, BE 1010737, U.S. Pat. No. 5,009,599, FR 2382254, GB 1238975, U.S. Pat. No. 3,585,752, U.S. Pat. No. 3,496,670 and U.S. Pat. No. 1,472,536. 
     SUMMARY OF THE PRESENT INVENTION 
     There is provided in accordance with a preferred embodiment of the present invention, a kit for a construction toy. The kit includes at least two construction blocks, where each construction block includes at least one hole which includes a ridged outer ring. The kit also includes at least one peg, sized to fit within a hole of the construction blocks, to connect between two of the construction blocks with a cam-releasable snap-on connection. Each peg includes at least 2 partially ridged outer rings to engage with the ridged outer ring of a hole when the peg is inserted into the hole to securely hold two construction blocks at a non-parallel angle. 
     Moreover, in accordance with a preferred embodiment of the present invention, the kit also includes an extraction tool. The extraction tool includes a separation element including a thin wedge-like edge to provide mechanical leverage between at least two connected construction blocks and an extraction tip that includes at least a curved and angled surface to engage with a curved and angled undersurface of the peg when engaged with one of the two construction blocks to remove the peg. 
     Further, in accordance with a preferred embodiment of the present invention, each construction block has multiple surfaces and the at least one hole is positioned on each surface of the construction block. 
     Still further, in accordance with a preferred embodiment of the present invention, the peg includes two snap-on connections, each connection to connect into one of the holes in the construction blocks, and two pairs of cam-releasable elements, each pair to overcome its associated snap-on connection thereby to enable the peg to be extracted from the construction blocks, and two inner rings, where the snap-on connections are on the inner rings and the cam-releasable elements are on the ridged outer rings of the peg. 
     Additionally, in accordance with a preferred embodiment of the present invention, the inner rings of the peg include a split lip to catch underneath an extension of an inner ring of a hole of one of the construction blocks and where the halves of the lip are pushed together when the peg is pushed into the hole. 
     Moreover, in accordance with a preferred embodiment of the present invention, the partially ridged outer rings have at least one tab with a curved and angled undersurface to receive a rotatable, curved and angled uppersurface, the uppersurface providing an upward force against the curved and angled undersurface, thereby to push the peg out of the block. 
     Further, in accordance with a preferred embodiment of the present invention, the angle is a multiple of the angle of curvature of the arc of the distance between the ridges of the outer ring of the at least one hole and the curvature of the arc of the distance between the ridges of the partially ridge outer ring of the peg and where the angle is pre-determined. 
     Still further, in accordance with a preferred embodiment of the present invention, each construction block rotates around the peg in increments of the angle. 
     Additionally, in accordance with a preferred embodiment of the present invention, the shape of the block is square, rectangular, triangular or an arc. 
     Moreover, in accordance with a preferred embodiment of the present invention, the shape of the block is one of: suns, moons, stars, plants and trees, arches, architraves, balusters, columns, wheels, gear wheels and cogs, spur, helical, double helical, double helical, skew, bevel, spiral bevel, worm, rack and pinion. 
     Further, in accordance with a preferred embodiment of the present invention, the peg is at least one of: double, triple, quadruple and multi-headed. 
     Still further, in accordance with a preferred embodiment of the present invention, the shape of the extraction tool is at least one of: elliptical, square, triangular and rectangular. 
     There is provided in accordance with a preferred embodiment of the present invention, a peg for connecting together two construction blocks. The peg includes two snap-on connections, each connection to connect into a hole in one of the construction blocks, and two pairs of cam-releasable elements, each pair to overcome its associated snap-on connection thereby to enable the peg to be extracted from one of the blocks. 
     Moreover, in accordance with a preferred embodiment of the present invention, the peg has two inner rings and two outer rings and the snap-on connections are on the inner rings and the cam-releasable elements are on the outer rings. 
     Further, in accordance with a preferred embodiment of the present invention, the outer rings have at least one tab with a curved and angled undersurface to receive a rotatable, curved and angled uppersurface, the uppersurface providing an upward force against the curved and angled undersurface, thereby to push the peg out of the block. 
     Still further, in accordance with a preferred embodiment of the present invention, the peg is at least one of: double, triple, quadruple and multi-headed. 
     There is provided in accordance with a preferred embodiment of the present invention, an extraction tool for extracting a peg from a construction block. The extraction tool includes an extraction tip that includes at least a curved and angled surface to engage with a curved and angled undersurface of the peg and a separation element that includes a thin wedge like edge to provide mechanical leverage. 
     Moreover, in accordance with a preferred embodiment of the present invention, the shape of the extraction tool is at least one of: elliptical, square, triangular and rectangular. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings in which: 
         FIG. 1  is a schematic illustration of three blocks held together by pegs, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 2A and 2B  are enlarged schematic illustrations of the peg of  FIG. 1 , constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 3A and 3B  are schematic illustrations of the insertion of a peg within a block, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIG. 4A  is a schematic illustration of a single peg connecting two blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIG. 4B  is a schematic illustration of how two pegs may be inserted within the same block, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 5A, 5B and 5C  are schematic illustrations of the different permutations of connection blocks with pegs, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 5D, 5E and 5F  are schematic illustrations of the use of angles between connection blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIG. 6A  is a schematic illustrations of an extraction tool, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIG. 6B  is a schematic illustration of the use of the extraction tool of  FIG. 6A  to provide mechanical leverage when manually separating two adjoined blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 7A, 7B and 7C  are schematic illustrations of the use of the extraction tip of the extraction tool of  FIG. 6A  when extracting an inserted peg, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 8A and 8B  are schematic illustrations of examples of different sizes of rectangular blocks constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 9A and 9B  are schematic illustrations of examples of different sizes of square blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 10A and 10B  are schematic illustrations of examples of sizes of triangular blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIGS. 11A and 11B  are schematic illustrations of examples of sizes of arc shaped blocks, constructed and operative in accordance with a preferred embodiment of the present invention; 
         FIG. 12  is a schematic illustration of double, triple and quadruple-headed versions of the peg of  FIGS. 2A and 2B , constructed and operative in accordance with a preferred embodiment of the present invention; and 
         FIG. 13  is a schematic illustration of different shapes for the extraction tool of  FIG. 6A , constructed and operative in accordance with a preferred embodiment of the present invention. 
     
    
    
     It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. 
     DETAILED DESCRIPTION OF THE PRESENT INVENTION 
     In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention. 
     Applicant has realized that certain features of pegs and construction blocks may be designed to allow for blocks to be connected on all sides. Applicant has further realized that particular features may be implemented within both the pegs and the blocks to provide a large connection force between the different elements and thus enable the construction of large and stable structures. 
     There is provided, in accordance with an embodiment of the present invention, a selection of differently shaped construction blocks  10  together with pegs  12 , as shown in  FIG. 1  to which reference is now made. The different shapes may include but are not limited to square, rectangular, triangular and arc-shaped blocks, as described in more detail herein below.  FIG. 1  illustrates two square shaped blocks and a triangular shaped block connected in series using pegs  12 . It will be appreciated that typical dimensions for a square block may be 30 mm by 30 mm by 10 mm high. It will be appreciated that when two blocks  10  are connected together by a peg  12 , peg  12  may be hidden as is illustrated by the dotted lines in  FIG. 1 . 
     Each peg  12  may be used to connect together any two blocks  10 . An extraction tool  14  (described in more detail with respect to  FIGS. 6A and 6B ) may be used to extract a peg  12  which was previously inserted in to a block  10 . 
     It will be appreciated that each individual block  10  may comprise a number of insertion holes  16 . Each hole  16  may be situated on a different side of block  10  as well as on the upper and lower surfaces of a block  10 . The latter are typically in the geometrical center of the upper and/or lower surfaces. It will also be appreciated that arc shaped blocks  10  do not have a geometrical center and that the formation of holes  16  may be a particular pattern of facing of the holes  16  from the sides. The number of holes  16  to a block  10  may vary according to the shape and size of block  10 . 
     Each insertion hole  16  may comprise a ridged outer ring  18  and a non-ridged flat inner ring  20 . Ridged outer ring  18  may allow for the insertion and turning of peg  12  as is described in more detail herein below. Flat inner ring  20  may extend a distance D to a lower ledge  22  as is shown in  FIGS. 3A and 3B . 
     Reference is now made to  FIG. 2A  which illustrates a single peg  12 . As is shown, peg  12  is symmetrical and each peg  12  may comprise two outer rings  30 , four tabs  44  (only two are visible in  FIG. 2A ) and two inner rings  34  (only one is visible in  FIG. 2A ). Inner ring  34  is described in more detail in relation to  FIG. 7A . Each tab  44  may extend towards its inner ring  34  and may have a curved and angled undersurface  46  as is illustrated in  FIG. 2B  to which reference is now made. Each outer ring  30  may have partially ridged edges  32 . Each inner ring  34  may further comprise a lip  36  split into two halves with a channel  40  between the two halves. Each channel  40  may allow for the two halves of lip  36  to be squeezed together as is described herein below. 
     It will be appreciated that a user may insert peg  12  into hole  16 , as shown in  FIGS. 3A and 3B  to which reference is now made, and may continue pushing downwards with some force. This downwards force may push the relevant inner ring  34  and lip  36  of peg  12  into inner ring  20  of hole  16  in block  10 . Lip  36  may have an angled uppersurface  56  and an angled lower surface  38  which may aid the insertion of peg  12  into inner ring  20 . 
     It will be appreciated that the downward force on peg  12 , once inserted into hole  16 , may cause the two halves of lip  36  to be pressed towards each other, thereby shrinking channel  40  as is illustrated in  FIG. 3A . Once inner ring  34  of peg  12  has traveled length D within inner ring  20  of block  10 , it may encounter ledge  22 . At this point, there is room for the two halves of lip  36  to spread out and each catch underneath a ledge  22  with a snap, thus holding peg  12  in place within hole  16 , as illustrated in  FIG. 3B . In addition, a top  17  of outer ring  30  of peg  12  may bump up against an upper ledge  23  between ridged outer ring  18  and flat inner ring  20  of block  10  to ensure peg  12  comes to a stop in its correct position once it has been inserted. 
     It will be further appreciated that since the two halves of lip  36  catch under ledge  22 , peg  12  may be firmly held within block  10 . Accordingly peg  12  may be used to connect two blocks  10  to each other 
     Reference is now made to  FIG. 4A  which illustrates how peg  12  may be symmetric around an axis  42  and thus may connect two blocks  10 A and  10 B. One half of peg  12  may be inserted into a hole  16 A of block  10 A and the other half may be inserted into a hole  16 B of block  10 B. As is shown, due to the two halves of lip  36  catching under ledges  22 A and  22 B, peg  12  may be firmly locked into position between blocks  10 A and  10 B. 
     Reference is now made to  FIG. 4B  which illustrates how a single block  10  may accommodate more than one peg  12  in a hole  16  at any one time (in this scenario pegs  12 A and  12 B are connected from either side of block  10 ). It will be appreciated that the number of pegs that can be inserted into block  10  may depend on the number of holes  16  available. 
     Reference is now made to  FIGS. 5A, 5B, 5C, 5D, 5E and 5F  which illustrate how differently shaped blocks  10  may be connected together in different ways using pegs  12 . It will be appreciated that this ability is due to the uniformity of size of holes  16  over all types of blocks  10 .  FIG. 5A  shows blocks  10  connected in series. 
     It will be further appreciated that, since hole  16  may also be located within the upper and lower surfaces of block  10 , different blocks  10  may also be “stacked” as is illustrated in  FIG. 5B . 
     It will also be appreciated that once peg  12  is held in place within hole  16 , ridges  32  ( FIG. 2A ) of peg  12  may engage with ridges  18  ( FIG. 1 ) of hole  16 , enabling peg  12  to turn and to remain in place at a particular angle, thereby allowing two blocks  10 A and  10 B to be connected at an angle to each other, as is illustrated in  FIG. 5C . It will also be appreciated that the width of ridges  18  and  32  may be predetermined and may span a small angle α, which may be an integral fraction of a full circle (i.e. 360°). For example, the small angle α might be 15°. 
     The particular angle that a user may choose to have between any two of his/her blocks will be a multiple of angle α. It will be appreciated that the blocks will be held securely at the selected angle by the engagement of the two sets of ridges  18  and  32 . This may enable a user to create strongly angled structures as well as sturdy structures with curved surfaces, as is illustrated in  FIGS. 5D, 5E and 5F . In  FIG. 5D , each block  10  is rotated at exactly the same angle in order to create a perfect circle.  FIGS. 5E and 5F  show how other shapes, with other angles, may also be created with the same precision. 
     Thus, rectangular blocks  10  (for example) may be used to create constructions having curvatures (including 3D objects) without the need for a purposely designed shaped block  10  in order to provide the desired curvature. 
     It will be also appreciated that, when separating two adjoined blocks  10  from each other, the first block  10  may be manually pulled off peg  12 , blocks  10  generally being of a suitable size to allow for a hand to grip them. It will be further appreciated that once the two adjoined blocks  10  have been separated, peg  12  may be too small for human hands to easily remove it from the second block  10 . Reference is now made to  FIG. 6A  which details an extraction tool  14  designed to pull peg  12  out of hole  16  and thus out of block  10 . Extraction tool  14  may comprise a handle  50 , which may be of any suitable size and shape but may be large enough for a hand to hold and to twist it, an extraction tip  52 , a separation element  60  and an insertion tip  65 . Insertion tip  65  may be used, if needed, to insert and guide peg  12  into hole  16 . Extraction tip  52  may further comprise two active surfaces  54  which may be curved elements with a curved and angled uppersurface  56  (only one active surface is shown in  FIG. 6A ). Each surface  54  comprises a protrusion  57 . It will be appreciated that the function of protrusion  57  is to guide extraction tip  52  into hole  16 . 
     As is illustrated in  FIG. 6B  to which reference is now made, separation element  60  may have a thin wedge-like edge and may be used to provide mechanical leverage when manually separating two adjoined blocks  10 . 
     Reference is now made to  FIGS. 7A, 7B and 7C  which show extraction tip  52 , in use with peg  12 . In  FIG. 7A , extraction tip  52 , with its curved and angled uppersurface  56 , is positioned above peg  12  ready to be lowered and pushed into peg  12 . 
     It will be appreciated that a user may insert extraction tip  52  by pushing it into peg  12  and twisting it slightly according to arrow  51  so that each curved and angled uppersurface  56  may engage curved and angled undersurface  46  of tab  44  as is seen in  FIG. 7B . As can be seen, extraction tip  52  may fit between outer ring  30  and inner ring  34  such that curved and angled uppersurfaces  56  may engage under curved and angled undersurfaces  46 . 
       FIG. 7C  illustrates how extraction tip  52  may be twisted in the direction of tab  44  along curved and angled undersurface  46 . Curved and angled uppersurface  56  may push curved and angled undersurface  46  in a motion similar to that of a cam pushing a moveable surface. It will be appreciated that rotating extraction tip  52  may cause curved and angled uppersurface  56  to rotate and push against the curved undersurface of tab  44  and in the process push tab  44  upwards in the direction of arrow  60 . The rotation of extraction tip  52  is indicated by arrow  62 . 
     It will be further appreciated that since the two surfaces ( 46  and  56 ) are engaged, the upper motion in the direction of arrow  60  may overcome the force of connection of lip  36  caught underneath ledge  22  as was illustrated in  FIG. 3B . It will be appreciated that, as extraction tool  14  pulls peg  12  upwards, the strong upper motion may force the two halves of lip  36  to be squeezed against each other, thus allowing peg  12  to be pulled upwards, in a motion similar to that illustrated in  FIG. 3A , out of hole  16  and out of the pertinent block  10  to which it was inserted. It will be further appreciated that angled surfaces  37  and  38  of lip  36  may aid the upward movement of peg  12 . 
     It will be appreciated that peg  12  and extraction tool  14  may be made from very strong plastics such as Delrin  100 P for peg  12  and ABS (acrylonitrile butadiene styrene) for extraction tool  14 , strong enough to survive almost unlimited insertions and extractions. They may be manufactured by methods such as injection molding and 3D printing. 
     It will be further appreciated that peg  12  may be subjected to both a snap-on insertion motion (via the two halves of lip  36  and channel  40  there between) and a cam-releasable extraction motion (via tab  44  and extraction tip  52 ) due to the cam-releasable elements of peg  12  in order to release lip  36  from underneath ledge  22 . This combination enables peg  12  to be easily inserted into and extracted out of block  10  and also enables a very strong connection due to the fact that lip  36  may be caught underneath ledge  22 . It will be appreciated that this snap-on connection may generally only be overcome using the cam-releasable extraction motion provided by extraction tool  14 . 
     Further, inner ring  20  of block  10  may enable the insertion of peg  12  and the connection between two blocks  10  while outer ring  18  may enable the relative rotation of two blocks  10 . 
     Reference is now made to  FIGS. 8A, 8B, 9A, 9B, 10A, 10B, 11A and 11B  which illustrate some of the different shapes and sizes that may be typically available for block  10 .  FIGS. 8A and 8B  illustrate the rectangular range,  FIGS. 9A and 9B  illustrate the square range,  FIGS. 10A and 10B  illustrate the triangular range and  FIGS. 11A and 11B  illustrate the range of arc shaped blocks. As can be seen, the larger the block  10 , the more holes  16  that may be available for connecting purposes. 
     It will be further appreciated that both block  10  and peg  12  may have alternative types, shapes and other configurations that may generally conform to the standard principles of the hole and peg connection as discussed herein above. 
     Block  10  may take the form of elements of the natural world (suns, moons, stars, plants and trees), may take the form of ornamental architectural pieces (arches, architraves, balusters, columns etc.) or may take the form of mechanical elements (wheels, gear wheels and cogs). Block  10  may also take the form of gears (spur, helical, double helical, double helical, skew, bevel, spiral bevel, worm, rack, pinion etc.) as well as geometrical 2D and 3D shapes (ellipses, hexagons, trapezoids, cubes, helixes etc.) 
     Peg  12  may take the form of a double, triple, quadruple or multi-headed peg with various orientations as is illustrated in  FIG. 12  to which reference is now made, to allow for the construction of various angular orientations of blocks. 
     It will be appreciated that extraction tool  14  may also be of varying shape and size such as those illustrated in  FIG. 13  to which reference is now made, to be used with the construction and disassembly of blocks  10  and pegs  12  as described in more detail herein above. Other shapes, such as a rectangular shape, are included in the present invention. 
     Thus, the present construction block system may provide a system to build strong, sturdy and large constructions where various blocks may be held at various angles to each other due to the angular connection provided by the ridged outer ring  18  and the ridges  32  on peg  12 . 
     While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.