GB2543846A

GB2543846A - Toy construction set

Info

Publication number: GB2543846A
Application number: GB1519317.0A
Authority: GB
Inventors: Sumner Mark
Original assignee: Ncl Design Ltd
Current assignee: Ncl Design Ltd
Priority date: 2015-11-02
Filing date: 2015-11-02
Publication date: 2017-05-03
Also published as: GB201519317D0

Abstract

A toy construction set where the building block units are capable of frictional interconnection and wherein at least two of the units are made from a closed-cell polymer foam and have different Shore hardness values, densities or chemical compositions. Preferably the two units are formed of a combination of Polyethylene, Ethylene vinyl acetate EVA, rubber or polyolefin elastomers POE, with Calcium Carbonate. A first foam material may have a Shore C hardness of 60, and a density of 135. A second foam material may have a Shore C value of 60, with a density of 240 kg/m3. A third foam material may have a Shore C value of 45 and a density 185 kg/m3. There may three different types of unit: a constructor 33, a connector 133 and an adapter 32, 34.

Description

TOY CONSTRUCTION SET

The invention relates to a toy construction set comprising a plurality of units capable of interconnection to form a module, each module being in the form of a recognisable object, animate or inanimate, at least two of the units of each module being formed of a closed-cell polymer foam material of different material characteristics to one another.

Toy construction sets suitable for play and/or to assist learning in a creative environment are known. Sets capable of interconnection are known and provide the user with a multitude of construction options for connecting units in the set together to form objects which are recognisable, as animate, or inanimate, objects, or otherwise.

Sets comprising units formed of a closed-cell foam material are also known and are suitable for use in a wide variety of play and learning environments.

It is an aim of the present invention to provide an alternative construction set comprising a plurality of units which can be interconnected to form a modular object.

It is a further aim of the present invention to provide an alternative construction set comprising a plurality of units which can be interconnected to form a modular object which provides a tactile object for the user to interact and play with.

It is a yet further aim of the present invention to provide a construction set comprising a plurality of units which can be interconnected to form a modular object, the materials of the units is such as to allow improved connectivity of components for friction fit and hold due to the compound material characteristics.

The present invention provides, a toy construction set for play and/or to assist learning comprising a plurality of units capable of frictional interconnection with one another to form a module, at least two of the units of the module being formed of a closed-cell polymer foam material in which one or more of: Shore Hardness C, foam density and/or chemical composition are different between each unit of the at least two units, the module being a fabricated toy or plaything, each of the units permitting connection and disconnection with the other unit(s) of the module.

It is advantageous that the foam material of the units of the set is a closed-cell, chemically cross-linked expanded polymer foam material.

It is much preferred that the construction set comprises a plurality of units wherein the plurality of units are formed of two or more different foam materials. More specifically, the construction set comprises a plurality of units wherein at least two units are formed of two foam materials differing in one or more of: Shore Hardness C, foam density and/or chemical composition.

It is particularly preferred that at least two of the units of the module being formed of a closed-cell polymer foam material have different Shore Hardness to one another.

The foam material forming one or more of the units of the set may comprise one or more of: Polyethylene (PE), Ethylene vinyl acetate (EVA), Rubber andPolyolefin elastomers (POE).

In preferred embodiments, the foam material forming one or more of the units of the set may comprise Ethylene vinyl acetate (EVA) and one or more of: Polyethylene (PE), Rubber and Polyolefin elastomers (POE).

In certain embodiments, a foam material forming one or more of the units of the set comprises Ethylene vinyl acetate (EVA) and Polyethylene (PE.

In certain embodiments, a foam material forming one or more of the units of the set comprises Ethylene vinyl acetate (EVA) and one of more of Rubber and Polyolefin elastomers (POE).

The foam material may further comprise filler material. More specifically the filler material may be Calcium Carbonate (CaCOs).

More specifically, Table 1 shows embodiments of foam compositions for one or more units of a set according to the invention

Table 1 - Foam Compositions

In this way, the units may be formed of a material offering a tactile user experience and/or improved interconnectivity with adjacent units in the assembled module.

It is preferred that each foam material comprises Ethylene vinyl acetate (EVA) and a filler material and one or both of polyethylene and/or a polyolefin elastomer (POE). The POE may be rubber.

By providing a multiple component/unit construction set in various materials, the user is provided with tactile play and increased connectivity of components for friction fit and resistance to separation due to the compound material characteristics.

Preferably the foam material provides a tactile, soft touch material.

Preferably the foam material provides a smooth surface. In certain embodiments, the surface of the material comprises no surface texture.

Preferably the foam material provides construction adaptability. More specifically, each of the foam material units is rigid. More specifically, each unit is self-supporting.

Preferably the foam material units interconnect with other units by friction fit.

Preferably the foam material units provide an elastic surface. More specifically, the material of the surface of each unit may rebound and return to its starting profile following the application of compression, shearing, bending or stretching forces to the foam material of the unit.

In certain embodiments, the foam material of the, or each, unit of the set has elastic properties.

Preferably the foam material is a food grade material.

Preferably the units comprise rounded edges. In this way, the risk of injury in handling the units of the set may be reduced.

Preferably the foam material of the units is a light weight material, with a density range of 120 kg/m3 to 260 kg/m3.

Preferably the foam material is chemically inert.

Preferably the foam material is UV resilient.

Preferably the foam material is waterproof.

Preferably the foam material has good buoyancy for adaptive in or out of water use.

Each unit in the construction set is preferably cut from a sheet of foam material.

Preferably each unit is die-cut from the sheet of foam material. Each unit may be cut from the sheet of foam material using a CNC water-jet or CNC knife-cutting production methods.

It is preferred that the unit edge comprises a concave or convex sheared face of the unit. In this way, the concave and/or convex sheared face on the unit edge faces provide increased resistance for friction fit and resistance to separation on the, or each, adjoining unit(s) in an assembled module.

It is preferred that the one or more of the units of the set is formed from a sheet of foam material. Preferably, the foam material has a sheet thickness of greater than 8mm. More specifically, the foam material has a sheet thickness of about 8mm to 20mm. Most preferably the sheet thickness is 11mm.

It has been found that a foam sheet thickness of 11mm thickness provides units which are readily handled by the user. Below 8mm foam sheet thickness, the units are not well suited for the typical dexterity of users. At greater than 20mm sheet thickness, production becomes more difficult due to increased material deflection, which also results in decreasing the friction fit and connectivity of units.

It is preferred that each unit is formed of a closed-cell polymer foam material. In the construction set of the invention, it is preferred that within the plurality of units, there are at least two units in which the chemical and/or physical properties of the foam material are different.

In certain embodiments, a first foam material forming one or more units of the set preferably has Shore C hardness in the range of 50-70. The first foam material preferably has a Shore C hardness of 60.

It is known that the foam material density (kg/m3), has a direct correlation to the Shore C hardness value, increasing the density/volume of certain compounds in the foam material increases the Shore C value and decreasing the density/volume of certain compounds decreases the Shore C value.

In certain embodiments, a first foam material forming one or more units of the set preferably has a material density in the range of 120 to 150 kg/m3. Preferably the first foam material has a density of 135 kg/m3.

In preferred embodiments, the first foam material comprises 40% polyethylene, 27% Ethylene vinyl acetate and 33% of a filler material such as calcium carbonate. In much preferred embodiments, the foam material preferably has a Shore C hardness of 60 and a density of 135kg/m3. This foam material has a smooth outer surface with minimal deflection under tooling. It is rigid and impact resistant in normal play usage. The foam has minimal compression properties and has a uniform, closed cell structure.

It has been found that performing qualities outside these parameters decrease the connective capability with increased or decreased deformation under tooling application compromising the strength in joining units in both ‘lateral-connection’ and ‘cross-connectivity’.

In certain embodiments, a second foam material forming one or more units of the set preferably has Shore C hardness in the range of 55-65. The second foam material preferably has a Shore C hardness of 60.

In certain embodiments, the second foam material forming one or more units of the set preferably has a material density in the range of 200 to 260 kg/m3. Preferably the second foam material has a density of 240 kg/m3.

Outside of the preferred parameters, the second foam material is found to be too rigid for useful compression in connectivity under tooling or is too similar to Material 3 to provide a tactile distinction during use.

In preferred embodiments, the further, or second, foam material forming one or more units of the set comprises 32% Ethylene vinyl acetate, 48% rubber/polyolefin elastomer and 20% of a filler material such as calcium carbonate. The foam material preferably has a Shore C hardness of 60 and a density of 240kg/m3. This foam material has a smooth outer surface with greater deflection under tooling than the first foam material, therefore providing greater friction in interconnection than the first foam material. It is rigid and impact resistant in normal play usage. The foam has minimal compression properties and has a uniform, closed cell structure which is tighter than the closed cell structure of the first foam material.

It has been found that performing qualities outside these parameters decrease the connective capability with increased or decreased deformation under tooling application compromising the strength in joining component parts in both ‘lateral-connection’ and ‘cross-connectivity’.

When compared to the first foam material, the second foam material provides increased resistive connectivity for joining adjacent units together, provides greater rebound following the application and release of a compression force and greater original form return properties.

The second foam material provides a lower resistance to compression force and deforms more easily under such a force than does the first foam material.

The Shore C hardness is tested, measured and recorded by means of a durometer which is a spring loaded indentation device, in which values are obtained as a function of the viscoelastic property of the material by means of a metal spherical tip on the spring loaded indenter pin of the device. Shore C is an intermediary scale used for measuring foam, sponges, hard rubbers and materials such alike giving a reading between 0-100.

In certain embodiments, a third foam material forming one or more units of the set preferably has Shore C hardness in the range of 40-55. The third foam material preferably has a Shore C hardness of 45.

In certain embodiments, the third foam material forming one or more units of the set preferably has a material density in the range of 150 to 200 kg/m3. Preferably the third foam material has a density of 185 kg/m3.

Outside of the preferred parameters, the third foam material is found to be too soft for useful connectivity or is too similar to Material 2 to provide a tactile distinction during use.

In certain embodiments, the further, or third, foam material forming one or more units of the set comprises 40% Ethylene vinyl acetate, 30 % rubber/polyolefin elastomer and 15% of a filler material such as calcium carbonate. The foam material preferably has a Shore C hardness of 45 and a density of 185kg/m3. It has been found that performing qualities outside these parameters decrease the connective capability with increased or decreased deformation under tooling application compromising the strength in joining component parts in both ‘lateral-connection’ and ‘crossconnectivity’.

The third foam material has greater friction in interconnection than the first foam and the second foam materials. It has decreased rigidity when compared to the first or the second foam materials.

The third foam material has greater compression properties and has a uniform, closed cell structure which is larger than the closed cell structure of the first foam material due to the greater expansion at the point of manufacture.

When compared to the first and second foam materials, the third foam material provides decreased resistive connectivity for joining adjacent units together, provides greater rebound following the application and release of a compression force and greater original form return properties.

The third foam material provides a lower resistance to compression force and is very flexible when compared to the first and second foam materials.

In various embodiments, alternative polymer combinations, providing the same chemical parameters and physical characteristics to those of the first, second and third foam materials may be provided.

It is preferred that the first and second foam materials have a hardness of Shore C 60. In this way, one or more foam material units formed of polymer materials with the preferred Shore C Hardness of 60 may be included in the toy construction set in addition to, or as an alternative to, further units formed of the first, second and/or third foam materials.

In the toy construction set according to embodiments of the invention, the plurality of units preferably comprises one or more unit types. More specifically, each unit forming a module may a constructor unit, a connector unit and an adapter unit.

It is preferred that, each construct unit has dimensions which are larger than a connector or an adapter unit. More specifically, the length and/or breadth dimension of a construct unit is preferably larger than the length and/or breadth dimension of a connector and/or the length and/or breadth dimension of an adapter unit.

Each construct unit is preferably used for larger assemblies, vertical builds, and/or flat assembly or as a basis to create smaller construction modules.

In forming a module, in preferred embodiments, connection between adjacent units may be provided between all unit types. More specifically, in each module, a construct unit may be connected to one or more connector units and/or adapter units.

In certain embodiments, the, or each, construct unit is formed of the first or second form material. Such construct units have rigidity and connective strength.

It is preferred that a construct unit is formed of the first foam material. In this way, the construct unit has good self-supporting physical properties. This is particularly advantageous with large footprint construct units.

Medium and small footprint construct units are preferably formed of the first and/or the second foam material.

The third foam material is not suitable for construct units due to the undesired properties of increased flexibility and decreased rigidity.

One or more of the units may further comprise a pigment. A connector unit is preferably located between a construct unit and a further unit.

In order that the invention is readily understood and easily carried into effect, reference will be made to the accompanying drawings in which:

Figure 1 shows a cross connection between two interconnected construct units forming a module for use in a toy construction set;

Figure 1a depicts an alternative module comprising a plurality of construct units in cross-connection and with vertical and lateral extension;

Figure 2 depicts an alternative module comprising a plurality of construct units in lateral interconnection;

Figure 3 depicts an alternative module comprising a plurality of construct units in flat interconnection;

Figure 4a depicts an alternative module comprising a plurality of units and formed of interconnected construct, adapter and connector units;

Figures 4ai to 4aiii depict the addition of further units to the module of Figure 4a to form a larger, more complex module;

Figure 4aiv depicts a toy boat constructed comprising the modules and units depicted in Figures 4a to 4aiii;

Figure 4av depicts a collection of adapter units from a first toy construction set according to the invention, some of which may be used in the construction of the toy boat of Figure 4aiv;

Figure 4avi depicts a collection of connector units from the first toy construction set according to the invention, some of which may be used in the construction of the toy boat of Figure 4aiv;

Figure 4avii depicts a collection of construct units from the first toy construction set according to the invention, some of which may be used in the construction of the toy boat of Figure 4aiv;

Figure 4aviii depicts the adapter, connector and construct units from the first toy construction set according to the invention, such of which may be used in forming the toy boat module of Figure 4aiv;

Figure 4aix depicts the tooling layout for the adapter, connector and construct units of the first toy construction set according to the invention;

Figures 5a, 5b, 5c and 5d depict an alternative toy construction set according to the invention;

Figure 5e depicts the tooling layout for the adapter, connector and construct units of the toy construction set of Figures 5a to 5d;

Figure 6a shows two connector units from the set of Figure 5b ready for interconnection with one another;

Figure 6b shows the connector units of Figure 6a in cross-connection with one another;

Figure 6c shows an alternative pair of connector units from the set of Figure 5b in cross-connection with one another;

Figure 7a shows a further pair of connector units from the set of Figure 5b in flat connection with one another;

Figure 7b shows a yet further set of connector units from the set of Figure 5b in flat connection with one another;

Figure 8a shows a module comprising a construct unit and an adapter unit in connection with one another;

Figure 8b shows a yet further module formed using adapter units and construct units from the construction set of Figure 5b in connection with one another;

Figure 9a shows a module comprising a construct unit, connector unit and adapter units to depict a character on a surf board, comprised of units depicted in figure 4aix;

Figure 9b shows a further module of a connector unit and adapter unit;

Figure 10a shows a perspective view of units forming an animal toy construction set;

Figure 10b shows a plan view of units of Figure 10a;

Figure 10c shows in perspective view the tooling layouts for forming the units of the animal toy construction set of Figures 10a and 10b; and

Figure 10d shows in plan-view the tooling layouts for forming the units of the animal toy construction set of Figures 10a and 10b; and

Throughout the drawings, construct units are denoted by odd numbers lower than 100, adapter units are denoted by even numbers lower than 100, and connector units are denoted by odd numbers greater than 100. The tooling layout corresponding to the unit formed in the tooling layout is denoted by the number corresponding to the unit formed in the tooling layout with an additional apostrophe, for example, mould 32’ is used to form unit 32.

Where possible, like numerals are used to denote like elements throughout.

Figure 1 depicts a ‘cross-connection’ between two construct units forming a simple module. In such a module 1 is formed by connection between a first unit 3a and a second unit 3b, at least one of the planes including a surface 7 of the first unit 3a is perpendicular to the plane including the corresponding surface 9 of the second unit 3b, the connection is provided between the first unit 3a formed of first foam material connected to the second unit 3b formed of same first foam material.

The first closed-cell polymer foam material comprises 40% polyethylene, 27 % Ethylene vinyl acetate and 33% calcium carbonate filler and has a Shore C hardness of 60 and a density of 135kg/m3

One or more of the units (3a, 3b) of module 1 of the embodiment of Figure 1 provides structural support for modules having vertical or elevated horizontal modules. As is depicted in Figure 1a, a module 10 comprises a base 15 formed of a construct unit of the first foam material interconnected into which is the first construct unit 3a previously depicted in Figure 1. Construct units 11, 13 extend laterally from the first construct unit 3a to form a module 10 having an elevated horizontal construction above base 15.

The construct units 11, 13 are interconnected in ‘Cross-connection’. The plane including surface 12 of construct unit 11 is perpendicular to the plane including surface 14 of construct unit 13.

Construct units 11, 13 are formed of the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and has a Shore C hardness of 60 and a density of 135kg/m3.

Interconnection between units formed of the first foam material is most preferred in the modules of Figures 1 and 1a in which ‘cross-connection’ (Figure 1) and/or vertical or elevated horizontal models (Fig 1a) are formed as this offers the strongest structural support within the modules 1, 10.

As shown in Figure 2 and 3 respectively, modules 20 and 20’ are formed of a construct unit 21 formed from the first foam material and a construct unit 17 formed from the second foam material. The first foam material comprising 40% polyethylene, 27%% Ethylene vinyl acetate and 33% calcium carbonate and has a Shore C hardness of 60 and a density of 135kg/m3. The second foam material comprises 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3 A single plane includes corresponding surfaces 7 and 19 of the first construct unit 21 and the construct unit 17 in modules 20 and 20’ respectively. Module 20 exemplifies lateral extension of a module and module 20’ exemplifies flat connectivity of units in a module. In such arrangements, interconnection between units formed of foam materials having different chemical and physical properties is preferred due to the cohesive strength of the interconnection between the first and second foam materials forming those units.

The third foam material described herein is not suitable in modules 20 and 20’ as the components properties would be too flexible for the required interconnection of units 21 and 17.

Each toy construction set provides for assembly and disassembly of units forming a module.

In examples of a toy construction kit according to the invention, such as those in the depicted examples, units may be identifiable by size, by type/ format, by colour and/or by material. For example, construct units may be provided in a first colour in a kit, connector units may be provided in a second and different colour in the kit and/or adapter units may be provided in a third colour, differing from the first and second colours, in the kit.

By way of example, construct units may be larger than connector and/or adapter units in the same kit.

Construct units in a particular kit may be used for larger module assemblies, for vertical builds, and for flat assembly or as a base unit to create smaller construction modules. It should be understood that construct units may be used for other purposes in any kit.

Construct units are useful to connect between all unit types. Possible interconnection may be provided in a kit between two units as follows: ‘Construct unit’ to ‘Construct unit”; ‘Construct unit” to ‘Connecter unit” and/or ‘Construct unit” to ‘Adapter unit”.

Construct units are preferably formed from the first and/or the second foam material described herein. Such materials provide units that are self-supporting and which have connective strength to resist separation between interconnected units.

Ideally, the largest format construct units are best formed of the first foam material described herein. Such material is self-supporting.

Ideally, the medium format and smallest format construct units are best formed of the first of the second foam materials described herein.

The third foam material is not useful for construct units due to the undesired properties of increased flexibility and decreased rigidity.

Figure 4a depicts an alternative module 30 comprising a plurality of units. Module 30 is formed of a base construct unit 31, a vertically extending connector unit 131 interconnected with the base construct unit 31 and also adapter units 32a and 32b interconnected with the connector unit 131.

Figures 4ai to 4aiii show the stepwise addition of further adapter units 40 and connector units (57a, 57b, 49a, 49b) to the module 30 to form a larger, more complex module 300, being a toy boat as best seen in assembled form in Figure 4aiv.

As can best be seen in Figures 4a to 4aiv connector units are typically of medium footprint (when compared to the construct units).

The connector units (57a, 57b, 49a, 49b) are formed of the first or second foam material. The first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and has a Shore C hardness of 60 and a density of 135kg/m3. The second foam material comprises 32% Ethylene vinyl acetate, 48 % rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3.

The adapter units 40 are formed of the first, second or the third foam material. The third foam material comprising 40% Ethylene vinyl acetate, 45 % rubber / polyolefin elastomer and 15% calcium carbonate. The foam material preferably has a Shore C hardness of 45 and a density of 185kg/m3. In the depicted arrangement of Figure 4a to 4aiv, the adapter units 40 are formed of the third foam material comprising 40% Ethylene vinyl acetate, 45% rubber / polyolefin elastomer, a Shore C hardness of 45 and a density of 185kg/m3 and the adapter units 32a and 32b are formed of the second foam material comprising 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate, having a Shore C hardness of 60 and a density of 240kg/m3.

Figures 4av to 4avii depict the adapter, connector and construct units respectively of the first toy construction set depicted in full in Figure 4aviii. The layouts for wood-formed die tooling used for forming the units of the first construction set of Figure 4aviii are shown in Figure 4aix. As can be seen from the Figure, the layout of the tooling surface forming each of the shapes in which the units are formed are tessellated in the square, or rectangular orientation so as to ensure the use of material in the tooling is maximised.

Figure 4av depicts a first set of adapter units (even numbers 32 to 58). Some of the set of adapter units can be used in the construction of the toy boat module 300 of Figure 4aiv. Adapter units are typically smaller footprint parts when compared to connector and construct units of the invention.

The depicted adaptor units are primarily used for characterising assemblies such as wheels, wings, sails, eyes and so forth. Examples of various adapter units can be seen in Figures 4av, 5a, 8, 9 and 10a. Adapter units may be used to adapt modules comprising construct units and/or connector units.

Adapter units may be formed using any of the first, second and/or third foam materials herein described. The first and second foam materials provide adapter units with increased grip than those formed of the third foam material due to the decreased compression ratio and subsequent deflection under tooling. The third foam material has a greater tactile feeling and increased compression ratio which subsequently offers less resistance of connectivity in comparison to the first and second foam materials.

Figures 5a, 5b, 5c and 5d depict an alternative toy construction set according to the invention. Figure 5a shows the adapter units of this construction set formed of the second foam material. The second foam material comprises 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3. Alternatively, the adapter units may be formed of the third foam material comprising 40% Ethylene vinyl acetate, 45% rubber / polyolefin elastomer and 15% calcium carbonate and having a Shore C hardness of 45 and a density of 185kg/m3. It is envisaged that in certain embodiments, the alternative toy construction set depicted in Figures 5a to 5d may include adapter units formed of the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/cm3 and/or further adapter units formed of the second and/or third foam materials.

Figure 5b shows the connector units of the alternative construction set formed of the second foam material. The second foam material comprises 32% Ethylene vinyl acetate, 48 % rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3. Alternatively, the connector units may be formed of the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3. It is envisaged that in certain embodiments, the alternative toy construction set depicted in Figures 5a to 5d may include connector units formed of the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3 and/or further connector units formed of the second foam material.

Figure 5c shows the construct units of the alternative construction set formed of the first foam material. The first foam material comprises comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3. Alternatively, the connector units may be formed of the second foam material comprising 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3. It is envisaged that in certain embodiments, the alternative toy construction set depicted in Figures 5a to 5d may include connector units formed of the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3 and/or further connector units formed of the second foam material.

Figure 5d shows the alternative toy construction set comprising the adapter units, connector units and construct units of Figures 5a, 5b and 5c.

Figure 5e depicts the tooling layouts 600a, 600b, 600c, 600d, 600e, 600f, 600g, 600h and 600 j for the adapter, connector and construct units of the toy construction set of Figures 5a to 5d. The tools are preferably wood-formed die tooling made from premium Birch plywood with a high resin content for resilience and steel rule knives with a double bevelled edge for optimal cutting.

Figure 6a shows two connector units 137, 205 from the set of Figure 5b ready for interconnection with one another. In the depicted arrangement, the connector units are formed of the second foam material comprises 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3 The connector units 137, 205 are interconnected by friction fit to form the small module depicted in Figure 6b. The module formed of the two units may be repeatedly assembled and disassembled.

Figure 6c shows an alternative pair of connector units 189, 191 from the set of Figure 5b in cross-connection with one another. In the depicted arrangement, the connector units are formed of first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3.

Figure 7a shows a pair of connector units 181, 199 from the set of Figure 5b in flat connection with one another. In the depicted arrangement, the connector units are formed of second foam material comprising 32 % Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and having a Shore C hardness of 60 and a density of 240kg/m3. The module formed of the two units may be repeatedly assembled and disassembled.

Figure 7b shows a set of connector units 187, 189, 191 from the set of Figure 5b in flat connection with one another forming a small module. In the depicted arrangement, the connector units are formed of the second foam material comprising 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and having a Shore C hardness of 60 and a density of 240kg/m3. The module formed of the three units may be repeatedly assembled and disassembled.

Figure 8a shows a further example of a simple module comprising a construct unit 81 and an adapter unit 40 in connection with one another. Figure 8b shows a yet further module formed using adapter units 62 and construct units 63, 73 from the construction set of Figure 5d in connection with one another. As can be seen, a construction set according to the invention can be used to form simple (typically two to 10 units) or complex (typically more than 10 units) modules.

Figure 9a shows a further example of a simple module comprising a construct unit 13 in flat connection with adapter units 34 and 42, and in vertical connection with a connector unit 213 and a further adapter unit 46 connected to the free end of connector unit 213. The module 400 so formed depicts a surfer and surfboard toy.

Figure 9b shows a simple module formed of two units. Adapter unit 46 is releasably connected to connector unit 185 by friction fit. In certain preferred arrangements, the adapter unit 46 is formed of the third foam material comprising 40% Ethylene vinyl acetate, 45% rubber / polyolefin elastomer and 15% calcium carbonate and having a Shore C hardness of 45 and a density of 185kg/m3 and the connector unit 185 is formed from either the first foam material comprising 40% polyethylene, 27% Ethylene vinyl acetate and 33% calcium carbonate and having a Shore C hardness of 60 and a density of 135kg/m3 or the second foam material comprising 32% Ethylene vinyl acetate, 48% rubber / polyolefin elastomer and 20% calcium carbonate and has a Shore C hardness of 60 and a density of 240kg/m3.

Figures 10a to 10d depicts the units and tooling layouts for forming an animal toy construction set.

Figure 10a and 10b show a perspective and a plan view respectively of units forming an animal toy construction set in which the units for modules A (a crab), B (octopus), C (turtle), D (shark), E (seal), F (dolphin), G (crocodile), H (starfish), I (polar bear), J (fish), K (snake), L (whale), M (manta-ray), N (penguin), P (duck) and Q (duckling).

Figures 10c and 10d shows in perspective and plan view respectively the tooling layouts 500 for forming the units of the animal toy construction set of Figures 10a and 10b.

Claims

1. A toy construction set for play and/or to assist learning comprising a plurality of units capable of frictional interconnection with one another to form a module, at least two of the units of the module being formed of a closed-cell polymer foam material in which one or more of: Shore Hardness C, foam density and/or chemical composition are different between each unit of the at least two units, the module being a fabricated toy or plaything, each of the units permitting connection and disconnection with the other unit(s) of the module.

2. A toy construction set according to claim 1, wherein the at least two units are formed of two foam materials differing in one or more of: Shore Hardness C, foam density and/or chemical composition.

3. A toy construction set according to claim 2, wherein the at least two of the units of the module are formed of a closed-cell polymer foam material having different Shore Hardness to one another.

4. A toy construction set according to any one of the preceding claims, wherein the foam material forming one or more of the units comprises one or more of: Polyethylene (PE), Ethylene vinyl acetate (EVA), Rubber and Polyolefin elastomers (POE).

5. A toy construction set according to claim 4, wherein the foam material forming one or more of the units of the set further comprises Calcium Carbonate (CaC03).

6. A toy construction set according to any one of the preceding claims, wherein the foam material forming one or more of the units comprises Ethylene vinyl acetate (EVA), Polyethylene (PE) and Calcium Carbonate (CaC03).

7. A toy construction set according to any one of the preceding claims, wherein the foam material forming one or more of the units comprises Ethylene vinyl acetate (EVA), Polyolefin elastomers (POE) and Calcium Carbonate (CaC03).

8. A toy construction set according to any one of the preceding claims, wherein the foam material forming one or more of the units comprises Ethylene vinyl acetate (EVA), Rubber and Calcium Carbonate (CaC03).

9. A toy construction set according to any one of claims 1 to 5, wherein the foam material forming one or more of the units comprises Ethylene vinyl acetate (EVA) and a filler material and one or both of polyethylene and/or a polyolefin elastomer (POE).

10. A toy construction set according to any one of the preceding claims, wherein the foam material forming one or more of the units has a density range of 120 kg/m3 to 260 kg/m3.

11. A toy construction set according to any one of the preceding claims, wherein a first foam material forming one or more of the units has Shore C hardness in the range of 50-70.

12. A toy construction set according to claim 11, wherein the first foam material has a Shore C hardness of 60.

13. A toy construction set according to claim 11 or claim 12, wherein the first foam material forming one or more units of the set has a material density in the range of 120 to 150 kg/m3.

14. A toy construction set according to claim 13, wherein the first foam material has density of 135 kg/m3.

15. A toy construction set according to any one of claims 11 to 14, wherein the first foam material forming one or more units of the set comprises 40% polyethylene, 27% Ethylene vinyl acetate and 33% of a filler material.

16. A toy construction set according to claim 15 wherein the filler material is calcium carbonate.

17. A toy construction set according to claim 15 or claim 16, wherein the foam material has a Shore C hardness of 60 and a density of 135kg/m3.

18. A toy construction set according to any one of the preceding claims, wherein a second foam material forming one or more of the units has Shore C hardness in the range of 55 to 65.

19. A toy construction set according to claim 18, wherein the second foam material has a Shore C hardness of 60.

20. A toy construction set according to claim 18 or claim 19, wherein the second foam material forming one or more units of the set has a material density in the range of 200 to 260 kg/m3.

21. A toy construction set according to claim 20, wherein the second foam material has density of 240 kg/m3.

22. A toy construction set according to any one of claims 18 to 21, wherein the second foam material forming one or more units of the set comprises 48% rubber or polyolefin elastomer and 32% Ethylene vinyl acetate and 20% of a filler material.

23. A toy construction set according to claim 22 wherein the filler material is calcium carbonate.

24. A toy construction set according to claim 22 or claim 23, wherein the foam material has a Shore C hardness of 60 and a density of 240kg/m3.

25. A toy construction set according to any one of the preceding claims, wherein a third foam material forming one or more of the units has Shore C hardness in the range of 40 to 55.

26. A toy construction set according to claim 25, wherein the third foam material has a Shore C hardness of 45.

27. A toy construction set according to claim 25 or claim 26, wherein the third foam material forming one or more units of the set has a material density in the range of 150 to 200 kg/m3.

28. A toy construction set according to claim 27, wherein the third foam material has density of 185 kg/m3.

29. A toy construction set according to any one of claims 25 to 28, wherein the third foam material forming one or more units of the set comprises 30% rubber or polyolefin elastomer and 40% Ethylene vinyl acetate and 15% of a filler material.

30. A toy construction set according to claim 29 wherein the filler material is calcium carbonate.

31. A toy construction set according to claim 29 or claim 30, wherein the foam material has a Shore C hardness of 45 and a density of 185kg/m3.

32. A toy construction set according to any one of the preceding claims, wherein the plurality of units comprises one or more unit types.

33. A toy construction set according to claims 32, wherein each unit forming a module is one of: a constructor unit, a connector unit and an adapter unit.

34. A toy construction set according to claims 33, wherein each construct unit has dimensions which are larger than a connector or an adapter unit.