Patent Document

RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/862,151, filed on Oct. 19, 2006 (Attorney Docket Number 4008.3003US01). The entire teachings of the above application are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Building block toys have been popular for decades. The first block toys consisted of stackable solid blocks composed of wood or other materials. Plastic injection molding technology then enabled a variety of connectable plastic blocks, such as LEGO bricks. In general, plastic blocks rely on the precise fit of male and female connectors to produce structure. Other popular construction toys include magnetic and metal elements that use magnetic force to create a structure. 
         [0003]    Currently, inflatable blocks do exist that require traditional inflation via the use of human lungs or a pump. Like beach balls, these blocks inflate and then exist as standalone structures that can be connected to each other via hook-and-loop fasteners, adhesion, geometric fittings, or other means. 
         [0004]    Other inflatable structures include theme and holiday characters. Such structures are inflated by an air blower, which continuously runs to maintain positive air pressure within the structure. 
       SUMMARY 
       [0005]    In accordance with particular embodiments of the invention, an inexpensive air valve-connector can enable the construction of inflatable structures having multiple inflatable components. In particular, an inflatable component can be connected to an inflated structure and inflate without deflating the structure. The air valve-connector can be embodied in a low-cost building block toy. The air valve-connector can also be used to create other inflatable structures, such as decorations and signage. 
         [0006]    More particularly, an air valve-connector can allow air to flow between the two inflatable components, when subjected to a continuous flow of air. Specifically, positive air pressure generated by an air blower, i.e. a fan, is used to inflate a structure composed of one or more blocks that self-inflate upon connection to inflated blocks. 
         [0007]    One component of the toy building block is the air valve-connector, which comprises two light-weight connectors that can exist on opposite sides of the same block. The valve includes a compressible material, such as foam, that is actuated to open the valve. When two blocks are connected via the air valve, air is transferred from a first block to a second block. Particular embodiments feature the ability to create large lightweight low-cost structures that are fun to assemble and require minimal storage space. 
         [0008]    In accordance with one embodiment, a gas flow valve can include a housing and a block of porous material. 
         [0009]    The housing can include a first gas port and a second gas port. The housing defines a cavity such that air flows between the first gas port and the second gas port through a flow path within the cavity. 
         [0010]    The block of porous material can be disposed within the cavity, such that the flow path extends through the porous material. Furthermore, the porous material can be compressible, wherein the flow path extends through the porous material when the porous material is uncompressed and does not extend through the porous material when the porous material is compressed. 
         [0011]    In accordance with another embodiment, an inflatable structure can include an inflatable body and a plurality of valve connectors secured to the inflatable body. Each valve connector can include a housing and a block of compressible material. 
         [0012]    The housing can include a first gas port and a second gas port. The housing defines a cavity such that air flows between the first gas port and the second gas port through a flow path within the cavity. 
         [0013]    The block of compressible material can be disposed within the cavity to control the flow of gas through the flow path. Furthermore, the compressible material can be porous, wherein the flow path extends through the compressible material when the compressible material is uncompressed and does not extend through the compressible material when the compressible material is compressed. 
         [0014]    More particularly, the inflatable body can be fabricated form any desired shape, such as a toy block or an animated structure. Furthermore, the inflatable body is made from a porous or non-porous material. 
         [0015]    The valve connectors can include a male connector and a female connector. When assembled, a first valve connector can receive a continuous flow of air from a flow source. 
         [0016]    In accordance with another embodiment, a system for assembling an inflatable structure can include a plurality of inflatable components and a blower module. 
         [0017]    Each inflatable components can include an inflatable body and a plurality of valve connectors secured to the inflatable body. Each valve connector can include a housing and a block of compressible material. 
         [0018]    The housing can include a first gas port and a second gas port. The housing defines a cavity such that air flows between the first gas port and the second gas port through a flow path within the cavity. 
         [0019]    The block of compressible material can be disposed within the cavity to control the flow of gas through the flow path. Furthermore, the compressible material can be porous, wherein the flow path extends through the compressible material when the compressible material is uncompressed and does not extend through the compressible material when the compressible material is compressed. 
         [0020]    The blower module can provide a continuous flow of air through a source gas port, which is connectable to a first gas port of a component. 
         [0021]    In particular, each inflatable component can form a toy block or part of an animated structure. The toy blocks can be of various dimensions. Furthermore, the inflatable body can be made from a porous or non-porous material. 
         [0022]    The valve connectors can include a male connector and a female connector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
           [0024]      FIG. 1  is a perspective view of a female connector for an unconnected air valve-connector. 
           [0025]      FIG. 2  is a plan cross-sectional view of the female connector of  FIG. 1 . 
           [0026]      FIG. 3  is a perspective view of a male connector for an air valve-connector. 
           [0027]      FIG. 4  is a plan cross-sectional view of the male connector of  FIG. 3 . 
           [0028]      FIG. 5  is a perspective view of the air valve-connector in the connected state. 
           [0029]      FIG. 6  is a plan cross-sectional view of the air valve-connector in the connected state. 
           [0030]      FIG. 7  is a perspective view of an exemplary inflatable toy block employing the air valve-connector of  FIGS. 1-6 . 
           [0031]      FIG. 8  is a perspective view of another exemplary inflatable toy block employing the air valve-connector of  FIGS. 1-6 . 
           [0032]      FIG. 9  is a perspective view of a plurality of interconnected, self-inflating toy blocks. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    In accordance with a particular embodiment, a gas flow valve includes a housing and a moveable block of porous material. The housing defines a cavity such that air flows between a first gas port and a second gas port, through a flow path within the cavity. The block of porous material is disposed within the cavity such that the flow path extends through the block. Further details of particular female and male valve connectors are described below. 
         [0034]      FIG. 1  is a perspective view of a female connector for an unconnected air valve-connector. The female connector  1  includes a female housing  10  that can be injection molded or stamped from plastic or metal. The female housing  10  includes an open top connection port  19  bordered by a flange  13  for adhering the female housing to an inflatable device body, and a plurality of inflation ports  15 . As shown, the inflation ports  15  are shaped like window openings, but other openings or perforations can be used. Air flows into and out of the female connector  1  through the connection port  19  and the inflation port  15 . 
         [0035]    In this view a foam block  12  can be seen through the window openings  15 . The foam block  12  includes a center bore to fit over a compression column  16 . 
         [0036]    Also shown is a protective covering  14 , such as felt, for the foam block  12 . The protective coating can be a layer of low friction material, such as felt, a plastic cap, a polyester sticker, or the foam can be covered with an air tight elastomer. 
         [0037]    When the valve is unconnected, the foam block  12  inhibits, but does not necessarily prevent, air flow through the female connector  1 . While the foam block  12  obstructs the window openings  15 , the foam block  12  is porous so that air can escape from inside the inflatable device. This is important when the inflatable device is subjected to a continuous air flow, because if sufficient air cannot escape, the inflatable device can rupture. In a particular embodiment, the foam block  12  is fabricated from expanded low density polyethylene or polypropylene. 
         [0038]      FIG. 2  is a plan cross-sectional view of the female connector of  FIG. 1 . As shown, the central compression column  16  is integrally formed with the housing  10  and extends from a base portion  11  of the housing  10 . The foam block  12  can be adhered to the housing base  11 . The female housing  10  can also include internal flanges (not shown) to hold the foam block  12  in the internal cavity and in a compressed state. 
         [0039]      FIG. 3  is a perspective view of a male connector for an air valve-connector. The male connector  3  includes an internal housing  20  and an external housing  30  that can be injection molded or stamped from plastic or metal. The internal housing  20  includes a plurality of inflation ports  25  and the external housing  30  includes a plurality of connection ports  35 . Air flows into and out of the male connector  3  through the ports  25 ,  35 . The ports can be window-shaped openings as shown or use other perforations. In this view, a foam block  22  can be seen through the internal window openings  25  and a plunger  26  can be seen through the external window openings  35 . 
         [0040]    The internal housing  20  includes a flange  23  and the external housing  30  includes a flange  33 . The flanges are fastened together by a fastener, such as glue, with or without the illustrated clips  39 . Also shown are a plurality of pressure lips  37  that removably fasten the male housing  30  to the female housing  10  ( FIGS. 1-2 ). 
         [0041]    Like with the female connector  1  ( FIGS. 1-2 ), when the valve is unconnected, the foam block  22  is porous and fabricated from expanded low density polyethylene or polypropylene, and inhibits air flow through the male connector  3 . As such, air at a positive air pressure can escape from within an inflated block through the valve connector  3 . 
         [0042]      FIG. 4  is a plan cross-sectional view of the male connector of  FIG. 3 . In the male connector  3 , note that the plunger  26  is unconnected to the internal housing  20  and therefore can be freely moved against the foam  22 . The foam block  22  can be glued to the base  21  of the internal housing  20 . The internal housing  20  can also includes internal flanges (not shown) to hold the foam block  22  in the internal cavity and in a compressed state. 
         [0043]    Also shown is a protective covering  24 , such as felt, for the foam block  22 . Also note that the external housing  30  includes a central orifice  36 , which is dimensioned to receive the compression column  16  from the female housing  10  ( FIGS. 1-2 ). 
         [0044]      FIG. 5  is a perspective view of the air valve-connector in the connected state. In this view, the flange  13  of the female connector  1  is adhered to an inflatable body  55 F. 
         [0045]    To connect the valves, the male connector  3  and the female connector  1  are aligned, with the central orifice  36  of the external housing  30  aligned with the compression column  16  of the female housing  10 . The external male housing  30  is then inserted into the female housing  10 . The compression lips  37  engage with the female housing  10  at the window openings  15  to removably fasten the male housing  3  to the female housing  1 . 
         [0046]      FIG. 6  is a plan cross-sectional view of the air valve-connector in the connected state. As shown, a second inflatable device body  55 M is adhered to the exposed surface of the external housing flange  33 . 
         [0047]    The external male housing  30  further compressed the female foam block  12  so that the male external window opening  35  interface with the female window openings  15 . At the same time, the compression column  16  blocks the plunger  26  and forces the plunger  26  to further compress the male foam block  22 , thus opening the internal male window openings  25 . Air can now flow through the window opening ports  15 ,  25 ,  35 . 
         [0048]    While the foam valve has been shown having housings that are open cube shaped, with square profiles, the housing can be of any other suitable shape. In particular, the housings can be open cylinder shaped, with circular profiles. Furthermore, in other applications it may not be desirous for the foam blocks to be porous. In that case, porous foam blocks can be coated with an air tight material, such as rubber, urethane, or silicone. 
         [0049]    In a particular embodiment of the invention, a block unit comprises a body of a lightweight fabric or plastic with connectors that feature the proper structure and elasticity to execute the required connection. When deflated, the blocks require very little space for storage. When connected to an air flow, the blocks self inflate. 
         [0050]      FIG. 7  is a perspective view of an exemplary inflatable toy block employing the air valve-connector of  FIGS. 1-6 . As shown, the toy block  50 A is brick shaped with a body  55 A defined by a lightweight porous material, such as ripstop nylon fabric, polyester, treated cotton, or balloon foil. In another embodiment, the material can be non-porous, such as Mylar, acetate, LDPE, or rubber. As shown, the block  50 A includes one male connector  3 A and one female connector  1 A on opposite sides. The single-size block can be made in various dimensions, such as 12 inches high by 8 inches wide by 8 inches deep. 
         [0051]    In a particular embodiment, the body  55 A is fabricated from a LDPE film and the connector housings are fabricated from HDPE. The film is cut to size and folded to the desired shape. Once folded, the free edges are heat fused and excess material removed by heat snips. Those with ordinary skill in the art will recognize various other techniques for forming the desired shapes. The HDPE connector housings are then heat sealed to the LDPE body. 
         [0052]      FIG. 8  is a perspective view of another exemplary inflatable toy block employing the air valve-connector of  FIGS. 1-6 . As shown, the toy block  50 B is brick shaped with a body  55 B. Unlike the block  50 A of  FIG. 7 , the block  50 B includes two male connectors  3 B and two female connectors  1 B on opposite sides. As such, the double block  50 B would be twice as wide (e.g., 16 inches) as the single block of  FIG. 7 . 
         [0053]    Other blocks can have more connectors per side, such as triple size blocks (e.g., 24 inches). In each case, the blocks are expected to be assembled into vertical structures with the female connectors down and the male connectors up. 
         [0054]      FIG. 9  is a perspective view of a plurality of interconnected, self-inflating toy blocks. The blocks can be assembled in various ways to make various structures. Blocks can be fabricated in various colors or have printed surfaces to encourage the use of patterns to create images and shapes. In addition to the simple blocks of  FIGS. 7 and 8 , a blower unit  60  can be enclosed within a block  50 C. Such a blower block  50 C is expected to be placed directly on the ground and thus would not require a bottom female connector; instead there would be at least one male connector at the top (two as shown). 
         [0055]    Because the block structures are exposed to a continuous air flow, the blocks can wiggle or move to create an animated structure. Furthermore, the blocks can include additional features to create an audio sound, such as a whistle or musical tone, as the air is vented from the blocks. 
         [0056]    While this invention has been particularly shown and described with references to particular embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the embodiments without departing from the scope of the invention encompassed by the appended claims. For example, various features of the embodiments described and shown can be omitted or combined with each other.

Technology Category: 4