GB2531575A - Beads and bead assemblies - Google Patents

Abstract

The present invention is in relation to coloured bead blocks which are multifunctional in nature; they can be used in crafts to make shapes which can be fused together to create a more permanent structure or they be used to create three dimensional structures that can be rearranged. The beads are tubular three dimensional shapes with interlocking rounded dovetail grooves 1-4 that slide vertically to be connected with one another and be arranged in an array of different patterns. The beads can be permanently fused together via the nature of the composition that allows them to melt. Low porosity paper that is impermeable to oil or grease may be layered between the beads and an iron, this allows the beads to melt evenly and protect the iron and beads. By applying heat from an iron the surface of the plastic melts to create bonds, the result of this being a larger structure.

Description

Beads and Bead Assemblies This invention relates generally to interconnecting beads capable of permanent setting through the application of heat or otherwise.

In general, interlocking building block puzzles are known in the prior art, as are melting craft beads designed to be melted with a hot hand iron when a piece of paper which is impermeable to grease and oil is placed between the beads and the hot iron. The following patents are the closest prior art references which are related to the present invention.

1. 1960s (patented 1962, patent granted 1967) by Gunnar Knutsson in Vallingby, Sweden, 217875 This is the patent for the original peg boards that were used to mount plastic beads, originally designed as an exercise to aid elderly dexterity; they became popular as an arts and crafts toy, with beads made from polyethylene to be melted by applying heat. There is no way of securing the beads whilst creating the art, before they are sealed with heat, hence, if the peg boards are knocked the art will be destroyed.

2. Building blocks Publication number W01993010873 Al A large variety of different blocks, with a corresponding large variety of construction options. In a kit or collection of such building blocks, a combination of various configurations of such blocks is provided. One interconnection means is a dovetail groove, so that the blocks may slid ably engage. To build shapes other components other than the blocks are required, such as 'popsicle' sticks.

3. TOY BUILDING BLOCKS AND BASE Clarence Pool et al 2565823 A means of building blocks with grooves that attach so as to avoid toppling when stacked.

4. 'Building block' US 2472363 Toy building blocks are depicted with dovetail ribs and grooves on their sides. The purpose is to build imaginative designs that hold their shape by the grooves on the sides that can be shifted and modified. There are a variety of solid shapes. They have angular, sharp edges instead of curved edges and are solid as opposed to hollow. These sharp edges potentially could be dangerous, for the desired demographic..

5. Toy building block puzzle EP 0783908 B1 A building block toy made of different shapes designed to be used to make larger shapes. They have a hollow central bore extending throughout. They have grooves 10 and notches and pegs to connect to each other.

6. "Multi-Cube Puzzle" US 5,344,147 This patent discloses a multi-cube puzzle wherein there are female members and male members so that one can be inserted into the other to create a different design. The pieces contain colour elements to facilitate creation of a colour pattern design.

7. Selectively position able interlocking toy building block having swivelling and non-swivelling positions WO 1998035735 Al A set of building blocks to be interlocked in two different positions having both male and female features, engagable with one another in a first mating relationship in which the male features is fully inserted into the female feature and in a second mating relationship in which the male feature is only partially inserted into the female features.

8. Basic building blocks for constructing complex building structure US 5826394 A This invention relates to building blocks and building beams forming a basic structure for forming complex edifices. The invention particularly relates to building blocks and building beams which can be assembled easily by children in toy systems to form complex structures.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is front view of a block in accordance with aspects of the present invention; Figure 2 is an isometric view of the block depicted in figure 1 towards a female coupling; Figure 3 is a back view of the block depicted in figure 1 and figure 2; Figure 4 is an isometric view of the block depicted in figures 1 to 3 towards a male coupling; Figure 5 is a top view of the block depicted in figures 1 to 4; Figure 6 is a bottom view of the block depicted in figures 1 to 5; Figure 7 is a plan view of blocks in accordance with aspects of the present invention formed into an interlocking assembly; Figure 8 is an isometric view of the assembly as depicted in figure 7; Figure 9 provides a back schematic illustration of a three dimensional assembly; Figure 10 provides a front schematic illustration of a three dimensional assembly in accordance with aspects of the present invention; Figure 11 is a front view of the assembly as depicted in figure 9 and figure 10; Figure 12 is a back view of the assembly as depicted in figures 9 to 11; Figure 13 is a front view of an assembly as depicted in figures 9 to 12 with a covering; Figure 14 is a back view of the assembly as depicted in figure 13 with a covering; Figure 15 is an assembly with an Emoticon design; Figure 16 is an assembly with a letter design; and, Figure 17 is an assembly with a flower design; This invention aims to solve the problem that previous melt able craft beads and the like have, that they cannot hold their own structure without the use of a peg board and hence, are relatively easily disturbed or destroyed by inadvertent movements. The present invention can be built horizontally across or vertically upwards to create different three dimensional structures, which has not previously been capable for thermo-plastic craft beads. These beads hold their shape by the use of dovetail grooves.

The present invention is a hollow melt able plastic bead which can be made as appreciated by a person skilled in the technology from various plastics including recycled plastic material, in various sizes and depths that interlock with other building beads by male protrusions and female dovetail grooves to form three dimensional coloured mosaics and models that have the ability to hold their structure through the friction produced by the acute angles of the male and female connection. The beads can also then be 'set' using heat from a hand iron and/or other means such as wetting or drying. Low porosity paper that is impermeable to oil or grease, is layered between the beads and the hot iron, to allow the beads to melt evenly and protect both the hot iron and beads. The bead surface will locally melt to create a permanent structure with a smooth surface to retain the assembly design. Gaps between beads will usually be included in a design and are specifically created and provided to allow molten plastic to flow into creating permanent connection when the heat is removed and the plastic allowed to set.

The advantage of the present invention is that there is no need to use a pegboard to assemble the mosaic assembly of the design, instead the created mosaic design are freestanding so can be reviewed in a reversible association and possibly altered before more permanent setting in a permanent association with application of a hot iron or the like. This allows for greater creativity and also ease of use as the creator has more freedom in the designs they produce, the creations hold their shape and can be moved, whereas, previous bead designs would be destroyed unless sealed by heat. The creator of the design using the present invention has the choice to make their designs permanent by setting using heat from a hand iron, to build vertically using the interlocking system or to continue to change and adapt their created design. It will also be understood that a base part of a designed assembly can be made and set then additional parts added as a trial or test before then being set to the base part of the design assembly.

An example of a block in accordance with aspects of the present invention is illustrated in figures 1 to 6.These illustrations show aspects of the present invention from a variety of different angles whereby the shaping of male and female coupling parts are used to achieve acute engagement angles for frictional interference to hold the respective block positions in a designed assembly before permanently setting the design assembly as indicated.

The present invention has created advancement through interlocking features, combining and improving the concept of a building block, but, also the thermo bead io as it allows a three dimensional design assembly such as toys to be built with a large multiplicity of functions in both a crafts capacity and a building block toy. The beads can be in a multitude of colours including translucent and opaque materials. This variety of colours allows for mosaics of varying colour to be produced and to be creatively explored. Specific curves and angles of the beads may be chosen to allow space for molten material to flow and set to create the final form. The beads will have a draught taper angle in central hollow channel and/or male-female coupling elements to assist with manufacture and possibly to provide some friction interference engagement to bias retention in assembly. The taper angle will extend from one end of the block to the other and be of a few degrees (up to 3). The surface of the male and/or female coupling portions at least in part may be textured or roughed or treated/coated at least in part in manufacture or subsequently to increase or decrease friction with other beads in assembly for retention or to assist assembly.

Referring to figures 1 to 6, a top edge as depicted in figure 1 of a bead block 100 as depicted has a male coupling feature flange (1), on a bottom edge as depicted protrudes a female coupling feature (3), which acts as a socket for an opposed an interlocking male feature (1) in an assembly. A left edge as depicted in figure 1 has a male coupling feature (4) and a right edge as depicted has a female feature (2). The male and female couplings are in pairs and respectively opposed edges of the block so a male coupling is substantially perpendicular to a female coupling. This is to enable the bead blocks 100 to be stacked and placed in a variety of different ways to allow creativity in crafts and to promote imaginative thinking. All the corners are rounded (11) (12) (13) to promote a good feel in the hand and ease of use, whilst still maintaining the friction that stabilises the created models, through the connection between the male and female counterparts. Although substantially male and female couplings are perpendicular to each other it will also be appreciated that a slight deviation from perpendicular will create a strain in association between blocks about a male to female association which may help with friction and/or interference association of the blocks in an assembly at least when that association is reversible.

The male coupling flanges 1, 4 protrude outwards from both the top and the left edge as illustrated in figure 1 and can be seen from above (in figures 1 to 4). The female couplings are corresponding grooves located on both the right edge and the bottom edge as seen from above (figure 1.) have an indentation with acute angles (2) and (3) (figure 1). The interconnecting bead blocks 100 connect through dovetail grooves with corresponding male couplings (1) (4) and female (2) (3) flanges. Blocks can click together' and/or push together, where the elasticity within the material gives way to allow simple connectivity when the creator is forming their design.

The bead block 100 may be interconnected with any other bead block 100 by sliding the bead blocks together vertically, which results in the attachment of male and female coupling counter pads (figures3 and 4) The block beads 100 stay in place due to a frictional force keeping them together, which is created by the acute angles of the bead block edges. When connected as shown in figure (8) there will be an alignment of corners (11) and (13) and corners (12) and (13), (figure 3 and figure 4) which shows an example of the top male edge and the bottom female edge of two beads connected via the left female and right male dovetail grooves (8).

There is a hollow tubular central bore (6) in each of the beads. If heat is applied this hole or hollow centre reduces to result in a shiny smooth finish to the surface of (5) in figure 2. This finish is due to the nature of the plastics or other material the bead is made from. As the plastic melts this allows for new bonds to be created in order to keep the structure or assembly in place. Where four beads meet and create an intersection (Figure 3 and Figure 4) there will be two corners (11), a corner (12) and a corner (13) connected. Here, a small inlet of a diamond like shape (10) can be seen, this allows for the expansion of the plastic as it melts to form permanent bonds to the created shape or mosaic. The hollow centre 6 may also allow some flex in the block during assembly.

Unlike other well-known craft beads a pegboard is not required with a block in accordance with aspects of the present invention to assemble the bead blocks together. This is not required as all bead blocks have the ability to attach to their neighbour via the male and female coupling dovetail grooves consisting of male protrusions or flanges (1) (4) and female grooves (2) (3). This allows the product to be used as a melt able craft bead without the need for a peg board, as the product holds its shape even if knocked. The sturdy structure when female and male components are attached allows for the pattern to be transported with ease and for the creator to be able to hold and admire their work without the beads falling from the desired shape. It is then up to the creator of the designed assembly to decide if to make their creation permanent by applying heat or to continue to adapt flat or three dimensional models as required, that can be changed as the creator desires. The versatility of the product through the creator's autonomy over the style of craft they create promotes creative thought and enjoyment. The reversible association is by friction and interference between the male and female couplings and the permanent association provided by distortion of these couplings and new bonding across the couplings.

There can be different depth block pieces that use the same male and female coupling components and the friction method to interlock to create three dimensional models and mosaics of the bead blocks together. These will work by the same principle as the single bead blocks. For example, double or more multiples height bead blocks will add a third dimension, due to the beads being able to slide or connect via the female and male coupling dovetail grooves (1) (4). Varying sized beads can slide onto other beads at any point, even half way up the other corresponding piece; this allows for greater creativity in creating three dimensional shapes and mosaics block assembly designs. It will also be understood that the male coupling parts can be forced (connected) into the female coupling channel or grooves at a particular location to be retained by interference fit.

Aspects of the present invention provide as follows 1. A hollow melt able plastic bead block of different sizes that interlock with other building beads by male protrusions (1) (4) and female grooves (2) (3) to form three dimensional mosaics and models for craft and other purposes, that hold their structure by the interlocking grooves, without the need for a peg board, the beads formation can also be set using heat from a hot hand iron when low porosity paper that is impermeable to oil or grease, is layered between the beads and the hot iron, the heat will melt the surface to create a permanent structure of the connected bead blocks.

2. A bead block made from LDPE (or other material) plastic or a recycled plastics material designed to melt from heat from a hot hand iron.

3. A bead block assembly linked by male (1) (4) coupling protrusions and female coupling dovetail grooves (2) (3) that interlock by sliding together vertically, creating friction which allows the beads to hold a rigid structure until desired to be broken, or made permanent by heat and/or a press fit interference fit between the male and female couplings.

zo 4. A bead block which can be used with other blocks for education and arts and crafts, enjoyment purposes, to allow for colour patterns and mosaics to be produced.

5. A bead block which comes in an array of colours, including both translucent and opaque.

6. A bead block assembly which can be built into three dimensional shapes. The sliding or 'push fit' interlocking mechanism allows for the shapes to be built up three dimensionally and transported as a stable construction before stabilising by a setting process.

7. A bead block which can be provided in various sizes to allow for a greater creativity and diversity of possible designs.

8. An ironing bed can be used made from a silicone sheet (or other heat resistant material). Such silicone sheet is long lasting heat resistant component compared to prior peg boards which tend to become damaged (flatten and/or distorted) eventually by heat during a hot ironing process. The silicone sheet can be flat and mouldable as the beads interlocking mean that position is retained by that means and not by pegs.

As can be seen in figures 1 to 6 bead blocks 100 have a face dimension F which presents a regular square so that blocks 100 can be assembled as required in a known combination. The blocks 100 have a depth dimension D which defines in a layer of desired bead block assembly so the depth of that layer. The dimension D again will be regular but as described later the dimension may be a multiple of a standard so say 5mm, 10mm, 15mm and 20mm so that blocks can extend between layers to provide keying between layers for assembly strength. The blocks 100 will initially slide and/or click together in a reversible association which then by appropriate means be made permanent as described.

The surface of the blocks may have impregnated micro beads of adhesive which may be activated to create the permanent association by heat or otherwise so for example the sliding motion may release the glue by friction which then provides some lubrication for sliding and then can be activated to cure for permanent association between the blocks.

Figures 8 and 9 show a layer of blocks in an assembly 200 in accordance with aspects of the present invention so it will be appreciated the blocks are generally in plane and so the assembly 200 is flat. The assembly 200 is robust due to the number of male to female coupling associations whether in the reversible association or permanent association so it can be lifted and placed as required prior to being rendered in a permanent association. It will be appreciated that the blocks can be of the same depth or different depths so that the assembly can have stippled effect at least one side if flat on the other.

As will be understood by those skilled in the technology within the depth range of the bead blocks in an assembly 200 as shown in figure 7 and figure 8 these blocks can slide relative to each other so a flat 'sheet' assembly 200 can be formed and shaped into a dish or curved configuration over a former on one side. The assembly can then be reviewed and permanently set as described then a covering provided to cover the assembly for a smooth surface.

Figure 15 shows an Emoticon of a smiley face created with blocks of different colours whilst figure 16 shows an assembly itself in a letter shape A and figure 17 shows a flower design each formed of similar or dis-similar coloured blocks.

Heat as indicated is used to cause bonding and/or distortion of the male and female couplings for a permanent association but alternative for distortion at least are by fluid absorption and drying of the blocks so that they swell or shrink to cause a more permanent association of the blocks in an assembly. The fluid may be water or a hydrocarbon.

In terms of creating three dimensional structures it will be understood that blocks can be assembled in layers with male couplings engaging female couplings in a plane across the layer to form a flat plaque but for greater strength blocks of different length as be provide as shown in figures 9 to 12 to provide keying between the layers. Thus, single layer blocks 300, double layer blocks 301 and triple layer blocks 302 are combined to provide a three dimensional assembly with male and female couplings which slide and/or snap together to create a desired structural assembly 303 initially in a reversible association to allow alterations then this assembly can be rendered and set by permanent associations between the male and female couplings as described previously by heat and/or absorption swelling or drying etc. The heat can be by application of a hot iron or microwave or other radiation to active the bonding or deformation process.

It will be understood that desired bead block assemblies will or can act as a skeleton for a covering or coating to create a plaque, sculpture or model. Thus an assembly design can be determined by considering a desired plaque, sculpture or model which comprises blocks in accordance with aspects of the present invention and an assembly plan in layers. A block assembly design 400 as described in figures 9 to 12 can as illustrated in figure 13 and figure 14 then be covered with a covering 401 to create a model or sculpture. In such circumstances prototype models can be created rapidly with different coverings applied as required for final refinement then the block assembly and covering rendered permanent as required. Similarly, items or even human heads or the like may be scanned, a block assembly design determined as a scaffold or skeleton and then a covering applied to create a sculpture which may assist artists in developing figurines etc. It will be appreciated that the blocks can be made of any suitable material but must allow reversible association so need some mechanical/material strength for that but also can then be 'activated' by heat or otherwise to create the coupling deformation and/or bonding.

Typically bead blocks in accordance with aspects of the present invention will be available in suitable sizes but for inter-changeability these should be standardised or unitised so depths of 5mm and 10mm and a face dimension of 7.8mm squared.

It will be understood that by use of a relatively robust connection there is a reduced need for quick heat fusion to stop destruction of a design.

It will be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.