US20130115849A1

US20130115849A1 - Building block

Info

Publication number: US20130115849A1
Application number: US13/808,733
Authority: US
Inventors: Wang Han Yap
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-07-05
Filing date: 2011-07-04
Publication date: 2013-05-09
Also published as: WO2012005567A1

Abstract

A building block as an integral unit and formed complete by a single injection moulding process, having six faces with adjacent faces substantially perpendicular to one another and with at least two faces adapted to enable detachably interlocking engagement, by interlocking means, with a similar face of another building block or with one having similar conceptual design. Additionally the walls of the building block have substantially similar and uniform thickness. in a preferred embodiment, the building block (1) is substantially cubical in shape and with any of the six faces adapted to enable detachably interlocking engagement, by interlocking means in the form of spigots (20) and suitably positioned and matching sockets (21), with any of the faces of another substantially similar building block (1) or with one sharing substantially similar conceptual design. The building block (1) comprises connected integral sloping walls (28) forming a skeletal frame (5) and with the spigots (20) and the sockets (21) extending outwards from the faces of appropriate said integral sloping walls (28) and with said connected integral sloping walls (28), said spigots (20) and said sockets (21) formed complete in a single injection moulding process.

Description

BACKGROUND TO THE INVENTION

Building blocks as education aid and construction toys for children have been in existence for a long period of time. Very common are building blocks each having a top face with protrusions and a corresponding bottom receiving face. The building blocks are coupled together by having the protrusions on the top face of a lower positioned building block raised to fit onto the bottom receiving face of another building block that is positioned above or vice versa. Building blocks of this design are limited and less versatile as said building blocks can only be interlocked in a single direction.
Building block having multiple faces, specifically six faces, for coupling to one another similar building block is also available. Each of such building block is typically constructed using multiple pieces that are joined together to form the complete building block. In an example of such is a building block six individual pieces represented the faces are joined together at their edges to form the complete building block. Building blocks constructed using multiple pieces are not so robust and they tend to fall apart with frequent usage or rough handling. Manufacturing such building blocks tend to be more costly as several moulding processes are required to produce the multiple pieces in addition to the extra labour needed to assemble said multiple pieces together.
It is an objective of the present invention to present a building block that is an integral unit and having the advantages of simplicity, versatility and structural stability and does not come apart with frequent usage or rough handling.
It is a further objective of the present invention to present a building block that can be easily manufactured specifically by a single injection moulding process, having substantially similar and uniform wall thickness and without the need of any subsequent assembly work.

SUMMARY OF THE INVENTION

The building block of the present invention is an integral unit formed complete by a single injection moulding process, having six faces with adjacent faces substantially perpendicular to one another and with at least two faces adapted to enable detachably interlocking engagement, by interlocking means, with a similar face of another building block having similar conceptual design.
In the first preferred embodiment, the building block is substantially cubical in shape and with any of the six faces adapted to enable detachably interlocking engagement by interlocking means with any of the faces of another similar building block. Interconnected integral sloping walls within the building block collectively form the skeletal frame of said building block. Each face of the building block is arbitrarily sectioned into quarters and with a first interlocking means in two diagonally opposite quarters and a second interlocking means in the other two diagonally opposite quarters. The first interlocking means and the second interlocking means are complementary interlocking means with one adapted to detachably and cooperatively fitted into the other. For illustration purposes, said first interlocking means is in the form of a spigot while said second interlocking means is in the form of a socket. The spigots and the sockets extend outwards from the faces of appropriate integral sloping walls of the building block. Each spigot has a substantially annular cross-section while each socket has a circumferential wall and a plurality of ribs positioned upright on its internal face. Each socket is positioned and shaped to accept a corresponding spigot and with an interference fit formed between them when a face of a building block is interlocked to a face of another similar building block. The building block of the present invention is not restricted to that of the first preferred embodiment as described above. The building block can exists in various embodiments provided that the design concept is maintained ie. the building block is an integral unit and formed complete by a single injection moulding process, having six faces with at least any two of said faces each adapted to enable detachably interlocking engagement by similar interlocking means with a face of a similar another building block or with one bearing similar conceptual design.
The building block can be assembled with other similar building blocks in a number of orientations. The walls of the building block, inclusive of the spigots and the sockets have substantially similar and uniform thickness for good injection moulding practice. The building block is preferably made from resilient plastic material that is suitably adaptable for injection moulding and made complete by a single injection moulding process. This feature of being made complete by a single injection moulding process is distinctly different from building blocks of other inventions wherein each such building block is made by assembling more than one component together and with each of said component made by a separate moulding process.
These and other features, advantages and objectives of the present invention will be further understood and appreciated by those skilled in the art by the following specification, appended drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a unit of the first preferred embodiment of the building block of the present invention.

FIG. 1A shows a unit of the second preferred embodiment of the building block of the present invention.

FIG. 1B shows a unit of the third preferred embodiment of the building block of the present invention.

FIG. 2 shows a unit of building block of the first preferred embodiment stacked onto and coupled to a similar building block that is positioned below.

FIG. 2A shows section ‘X-X’ of FIG. 2 showing the relative positions of the spigots and the sockets when two building blocks of the preferred embodiment are interlocked to one another.

FIG. 2B shows an example whereby a unit of building block of the first preferred embodiment is stacked onto and coupled to two similar building blocks that are positioned below.

FIG. 3 illustrates how six imaginary pyramids to be closed up to one another to form the building block of the first preferred embodiment of the present invention.

FIG. 3A illustrates how six imaginary components to be closed up on one another to form the building block of the third preferred embodiments of the present invention.

FIG. 4 shows the skeletal frame, without the interlocking means, of the building block of the first preferred embodiment of the present invention.

FIG. 4A illustrates the skeletal frame, without the interlocking means, of the second and third preferred embodiments of the building block of the present invention.

FIG. 5 shows the top view of a face of the building block of the first preferred embodiment.

FIG. 5A shows an isometric view of part of the building block of the first preferred embodiment that is also sectioned along view ‘Y-Y’ indicated in FIG. 5.

DETAIL DESCRIPTION OF THE INVENTION

The building block of the present invention is an integral unit formed complete by a single injection moulding process, having six faces with adjacent faces substantially perpendicular to one another and with at least two faces adapted to enable detachably interlocking engagement, by interlocking means, with a similar face of another building block or with one having similar conceptual design.
In the first preferred embodiment, as shown in FIG. 1, the building block (1) is substantially cubical in shape and with any of the six faces (with at least two of the six faces but preferably with all six faces) adapted to enable detachably interlocking engagement by interlocking means with any of the faces of another similar building block (1) or with one having similar conceptual design. To provide a clearer illustration of the building block (1) of this embodiment, six imaginary and similar hollow pyramids (2) are used as illustration. Each hollow pyramid has four sloping walls (28) defined by four external surfaces (28 a), four internal surfaces (28 b) and a base (28 c) of substantially square frame shaped, with the internal surfaces (28 b) of the sloping walls (28) defining a pyramid shaped cavity. Said building block (1) is akin to having six imaginary and similar hollow pyramids (2), closed up onto each other and with an external surface (28 a) of a sloping wall (28) of a pyramid (2) in full contact and merged with the external surface (28 b) of the adjacent sloping wall (28) of another pyramid (2) to form integral sloping wall (28) and with the apexes (30) of said pyramids (2), or the projections of such, collectively meeting at a substantially common point. A view of the imaginary pyramids (2), with interlocking means present at the faces, before they close up onto each other is shown in FIG. 3. Each set of two contacting adjacent external surfaces (28 a) of the sloping walls (28) of the pyramids (2) is merged and becomes effectively an integral sloping wall (28). The outer periphery of the base (28 c) of the sloping walls (28) of each of the pyramids (2) defines the boundary of each of the six faces of the building block (1). The integral sloping walls (28) themselves are connected and collectively form the skeletal frame (5) of the building block (1) as shown in FIG. 4. The center of the skeletal frame (5) can be designed as a void i.e. without material present with said void created by suitable design of the injection mould. The interlocking means at each face of the building block (I) extends outwards from the faces of appropriate integral sloping walls (28) of the skeletal frame (5). In the first preferred embodiment of the building block (1), as shown in FIG. 1, each face of said building block (1) is arbitrarily sectioned into four quarters and with a first interlocking means present at two diagonally opposite quarters and a second interlocking means present at the other two diagonally opposite quarters. The first interlocking means and the second interlocking means are complementary interlocking means with one adapted to detachably and cooperatively fitted into the other. In this embodiment, to facilitate explanation of the invention by way of example which is not to be interpreted as limiting in configurations, the first interlocking means is shown as a spigot (20) while the second interlocking means is shown as a socket (21) in FIG. 1 and FIG. 5. At each face of the building block (1) the spigots (20) and the sockets (21) extend outwards from the faces of appropriate integral sloping walls (28) of the building block (1) as indicated in FIG. 5 and FIG. 5A. It is important to note that a main feature of the building block (1) of the present invention is that the connected integral sloping walls (28) of the skeletal frame (5) together with the spigots (20) and the sockets (21) are formed complete in a single injection moulding process. Each spigot (20) has a substantially annular cross-section and a top circumferential rim (23). An outer edge (24) borders the extremity of the quarter of the face of the building block (I) where a spigot (20) is located, as shown in FIG. 1, FIG. 5 and FIG. 5A. The socket (21) has circumferential wall (25) and a plurality of ribs (26) positioned upright on its internal face as shown in FIG. 1, FIG. 5 and FIG. 5A. Each socket (21) is suitably positioned at the face of the building block (1) and is shaped to accept a corresponding spigot (20) and with an interference fit formed between them when a face of a building block (1) is interlocked onto a face of another similar building block (1) or with one having similar conceptual design. Specifically an interference fit is effected between a spigot (20) and a socket (21) when the outer wall of said spigot (20) comes in contact with outer edges of the ribs (26). The height of a spigot (20) above the outer edge (24) is equal to or less than the height of the circumferential wall (25) of a socket (21) in order that said spigot (20) does extend far into said socket (21) so as to hit the integral sloping walls (28) when a building block (1) is interlocked onto another. Additionally when a building block (1) is suitably interlocked onto another similar building block (1), or one having similar conceptual design, the outer edges (24) of the quarters come in contact with the adjacent top edges of circumferential walls (25) of the sockets (21) at the interlocked faces of said building blocks (1).
The building block (1) can be assembled onto other similar building blocks (1) in a number of orientations. FIG. 2 shows a building block (1) assembled onto another similar building block (1) that is positioned below. A sectional view showing how the spigots (20) are fitted to the sockets (21) when a building block (1) is interlocked to another is provided in FIG. 2A. Shown in FIG. 2B is a building block (1) assembled onto two similar building blocks (1) that are positioned below. When viewed from the front and for the building blocks (1) to be suitably interlocked the upright distance ‘M’ between the centres of the diagonally positioned spigots (20) at the front face of a building block (1) is substantially equal to the upright distance ‘K’ between the centres of the closest adjacent spigots (20) of two suitably interlocked building blocks (1) i.e. one spigot (20) each at the front faces of said interlocked building blocks (1), as indicated in FIG. 2B. The number of ways that the building blocks (1) can be assembled together is not limited by the examples provided as there are numerous other ways to assemble said building blocks (1) in order to form the desired structural designs.
The building block of the present invention is not restricted to that of the first preferred embodiment as described above. The building block can exists in various embodiments provided that the design concept is maintained i.e. the building block is an integral unit and formed complete by a single injection moulding process, having six faces with at least any two of said faces each adapted to enable detachably interlocking engagement, with similar interlocking means, to a face of another similar building block or with one bearing similar conceptual design.
Shown in FIG. 1A and FIG. 1B are two other embodiments of the building block of the present invention. The first interlocking means and the second interlocking means are complementary interlocking means with one adapted to detachably and cooperatively fitted into the other. In these embodiments, to facilitate explanation of the invention which is not to be interpreted as limiting in configurations, the first interlocking means is shown as a spigot (20) while the second interlocking means is shown as a socket (21) in FIG. 1A and FIG. 1B, The building block (1 a) as shown in FIG. 1A, the second preferred embodiment, has on each of the four side faces a spigot (20) and a socket (21) both at the same level and positioned side by side while each of the top and bottom faces is sub-divided into four quarters and with a spigot (20) at each diagonal opposite quarters and a socket (21) each at each of the other opposite quarters. The building block (1 b) as shown in FIG. 1B, the third preferred embodiment, has four faces with each said face having three spigots (20) and three sockets (21) alternatively positioned with respect to one another and two end faces with each said end face having two spigots (20) and two sockets (21) also alternatively positioned with respect to one another. The building block (1 b) is akin to having two opposing spaced apart hollow pyramids (4) and four hollow hip roofs (3) closed up onto each other, as indicated in FIG. 3A., resulting in a skeletal frame (6) having connected integral sloping walls (31, 32) as indicated in FIG. 4A, Each hollow pyramid (4) has four sloping walls (32) defined by four external surfaces (32 a), four internal surfaces (32 b) and a substantially square frame shaped base (32 c), with the internal surfaces (32 b) of the sloping walls (32) defining a pyramid shaped cavity. The outer periphery of said base (32 c) defines the boundary of each of two faces of the building block (1 b). Each hollow hip roof (3) abuts two adjacent hollow hip roofs (3). Each hollow hip roof (3) has four sloping walls (31, 32) defined by two each of external surfaces (31 a and 32 a), two each of internal surfaces (31 b and 32 b) and a substantially rectangular frame shaped base (34), with the internal surfaces (31 b, 32 b) defining a hip roof shaped cavity. The outer periphery of said base (34) defines the boundary of each of the remaining four faces of the building block (1 b). The external surfaces (32 a) of the sloping walls (32) of each hollow pyramid (4) are in full contact and merged with the external surfaces (32 a) of the sloping walls (32) of the four abutting hollow hip roofs (3) and become effectively the integral sloping walls (32) of building block (1 b). The two external surfaces (31 a) of the sloping walls of each hollow hip roof (3) are in full contact and merged with the external surfaces (31 a) of the sloping walls (31 a) of two abutting hollow hip roofs (3) and become effectively the integral sloping walls (31) of building block (1 b). The interlocking means, which are the spigots (20) and the sockets (21) in this case, at each face of the building block (1 b) extends outwards from the faces of appropriate integral sloping walls (31, 32) of the skeletal frame (6). It is important to note that a main feature of the building block (1 b) of the present invention is that the integral walls (31, 32) of the skeletal frame (6) together with the interlocking means, in these embodiments are shown as the spigots (20) and the sockets (21), are formed complete in a single injection moulding process.
The building block (1) is preferably made from resilient plastic material that is adaptable for the injection moulding process. An important feature of the building block (1, 1 a, 1 b) of the present invention is that said building block (1, 1 a, 1 b) is an integral unit and formed complete by a single injection moulding process. For the building block (1) of the first preferred embodiment the integral unit mentioned is inclusive of the connected integral sloping walls (28) that form the skeletal frame (5), the spigots (20) and the sockets (21). Additionally the walls of the building block (1), inclusive of the integral sloping walls (28), the spigots (20) and the sockets (21) are designed to have substantially similar and uniform thickness. The building blocks (1, 1 a, 1 b) of the present invention, each as an integral unit and formed complete by a single injection moulding process, is distinctly different from building blocks of other inventions whereby each building block of other inventions is made from more than one component and with said components subsequently assembled together to form said building block. Additionally for the other inventions the components that are assembled to form the building blocks may not necessary have similar and uniform wall thickness,
The foregoing description is considered as illustration of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to all suitable modifications and equivalents may be restored to, falling within the scope of the invention.

Claims

1-14. (canceled)

15. A building block (1), substantially cubical in shape, having six faces, said building block (1) comprises:

a skeletal frame (5) formed by connected integral sloping walls (28) of six hollow pyramids (2) closed up onto each other, with the integral sloping walls (28) defining six pyramid shaped cavities of the skeletal frame (5) and with the external periphery of each substantially square frame shaped base (28 c) of the sloping walls (28) defining the boundary of a face of said building block (1); and

interlocking means on at least two faces of the building block (1), the interlocking means extending outwards from the appropriate said integral sloping walls (28) to enable detachable interlocking engagement by complementary interlocking means on a face of another substantially similar building block (1) and with said integral sloping walls (28) and said interlocking means being an integral unit and formed complete by a single injection moulding process.

16. A building block (1) as in claim 15 wherein said building block (1) is made from resilient plastic material suitably adaptable for injection moulding.

17. A building block (1) as in claim 15 wherein any of the six faces are adapted to enable detachably interlocking engagement by interlocking means with a face of another building block (1).

18. A building block (1) as in claim 15 wherein each face of said building block (1) is arbitrarily sectioned into quarters and with a first interlocking means at each of two diagonally opposite quarters and a second interlocking means at each of the other two diagonally opposite quarters, said first and said second interlocking means being complementary interlocking means

19. A building block (1) as in claim 18 wherein the first interlocking means is in the form of a spigot (20) while the second interlocking means is in the form of a socket (21).

20. A building block (1) as in claim 19 wherein each spigot (20) has a substantially annular cross-section with a top circumferential rim (23) and with an outer edge (24) borders the extremity of quarter of the face where said spigot (20) is present and each socket (21) is shaped and suitably positioned at the face to accept a corresponding spigot (20) and with said socket (21) having a circumferential wall (25) and with a plurality of ribs (26) in upright position on its internal face and an interference fit effected between said spigot (20) and said socket (21) when the outer wall of said spigot (20) comes in contact with the ribs (26).

21. A building block (1) as in claim 20 wherein the thicknesses of the walls of said building block (1) inclusive that of the integral sloping walls (28) that form the skeletal frame (5), the spigots (20) and the sockets (21) are substantially similar and uniform.

22. A building block (1) as in claim 21 wherein the upright distance ‘M’ between the centres of the diagonally positioned spigots (20) on the front face of a building block (1) is substantially equal to the upright distance ‘K’ between the centres of the closest adjacent spigots (20) one each on the front faces of two suitably interlocked building blocks (1).

23. A building block (1) as in claim 15 wherein center of the skeletal frame (5) is a void and without material present.

24. A building block (1 a, 1 b) having six faces with adjacent faces substantially perpendicular to one another, said building block (1 a, 1 b) comprises:

a skeletal frame (6) formed by connected integral sloping walls (31, 32) of four hollow hip roofs (3) and two spaced apart hollow pyramid (4) closed up onto each other, with four of the adjoining integral sloping walls (32) defining one of the two pyramid shaped cavities of the skeletal frame (6) and with two each of the adjoining sloping walls (31, 32) defining one of the four hip roof shaped cavities of the skeletal frame (6), with the external periphery of each substantially square frame shaped base (32 c) of the four adjoining sloping walls (32) defining the boundary of two of the faces of said building block (1 a, 1 b) and with the external periphery of each of the substantially rectangular frame shaped base (34) of two each of the adjoining sloping walls (31, 32) defining the boundary of four of the faces of said building block (1 a, 1 b); and

interlocking means on at least two faces of the building block (1 a, 1 b), the interlocking means extending outwards from the appropriate said integral sloping walls (31, 32) to enable detachable interlocking engagement by complementary interlocking means on a similar face of another substantially similar building block (1 a, 1 b) and with said integral sloping walls (31, 32) and said interlocking means being an integral unit and formed complete by a single injection moulding process.

25. A building block (1 a, 1 b) as in claim 24 wherein said building block (1 a, 1 b) is made from resilient plastic material suitably adaptable for injection moulding.

26. A building block (1 a, 1 b) as in claim 24 wherein any of the six faces are adapted to enable detachably interlocking engagement by interlocking means with a face of another building block (1 a, 1 b).

27. A building block (1 a, 1 b) as in claim 24 wherein the interlocking means comprises a first interlocking means and a second interlocking means, said first and said second interlocking means being complementary interlocking means, with said first and second interlocking means positioned alternate to one another on any of the faces of said building block (1 a, 1 b).

28. A building block (1 a, 1 b) as in claim 27 wherein said first interlocking means is a spigot (20) and said second interlocking means is a socket (21).

29. A building block (1 a, 1 b) as in claim 28 wherein the thicknesses of the walls of said building block (1 a, 1 b) inclusive that of the integral sloping walls (31, 32) forming the skeletal frame (6), the spigots (20) and the sockets (21) are substantially similar and uniform.

30. A building block (1) as in claim 24 wherein hip line of the skeletal frame (6) is a void and without material present.

31. A building block (1) as in claim 17 wherein each face of said building block (1) is arbitrarily sectioned into quarters and with a first interlocking means at each of two diagonally opposite quarters and a second interlocking means at each of the other two diagonally opposite quarters, said first and said second interlocking means being complementary interlocking means