Patent ID: 8850683

Claim:
A method of forming a toy block comprising: providing first and second separate solid block parts, each having at least one interior face, wherein said interior faces will face inwardly toward one another when said first and second parts are assembled into a block, said first block part having a bottom face opposite its interior face and said second block part having a top face opposite its interior face; forming on each said first and second parts at least three external side faces which will align when said first and second block parts are assembled together; forming in each said first and second block parts, either before or after forming said external faces thereon, at least one slot, oriented to mate with each other when said first and second block parts are coupled, each said slot extending from said interior face of its respective first or second block part, into said block part proximate and parallel to an external side face of said block part, each said slot having a depth accommodating only a portion of the diameter of a disc magnet to be located therein; forming a central bore in each said first and second block part, either before or after forming said external faces thereon, extending from its said interior face towards, and terminating internally proximate to and parallel to, its opposite bottom external face or top external face, respectively, said bores being located so as to align with one another when said first and second block parts are coupled together; disposing a disc shaped magnet in each said central bore of said first and second block parts, at the terminus of each said bore, parallel to its said bottom or top external face, respectively; inserting a spacer into one of said central bores to retain said magnets at respective terminal ends of its respective bore when said first and second block parts are assembled together; disposing a permanent disc magnet in each slot in said first block part, leaving said disc magnet partial exposed, the corresponding slot in said second part seating over said exposed portion of said disc magnet when said second block part is coupled to said first block part; coupling said first and second block parts together with said interior facing surfaces facing inwardly toward one another, and said corresponding external side faces of said block parts aligned, such that said disc magnet located adjacent said external side is directing a single polarity of magnetic field through said corresponding aligned external side faces.