US20170056782A1

US20170056782A1 - Posable Toy Linkage

Info

Publication number: US20170056782A1
Application number: US15/251,953
Authority: US
Inventors: Joseph Farco
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-08-30
Filing date: 2016-08-30
Publication date: 2017-03-02

Abstract

A linkage that couples a plurality of Lego blocks or Lego-like blocks is posable and configured to provide a plurality of three-dimensional orientations for the plurality of blocks it interconnects.

Description

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 14/474,276, filed on Sep. 1, 2014 and claims the benefit of U.S. Provisional Patent Application Ser. No. 62/211,822, priority to each of the aforementioned applications is hereby claimed and the disclosures of each of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

Disclosed are embodiments of the invention that relate to, among other things, building block linkage and joint systems and methods.

BACKGROUND

Linkages for toy building blocks, such as those made by LEGO®, Duplo®, Mega Bloks, Built to Rule, K'nex, Kre-O, and others, provide limited degrees of movement and positioning in the three dimensional plane for the blocks they connect.
Flexible plastic cables, string, plastic rods, and plastic tubes have been used to connect building blocks, as illustrated and described in U.S. Pat. Nos. 5,433,549, 5,733,168, 6,000,984, 6,213,839, 6,461,215, 6,676,474, 6,843,700, and PCT/DK1991/000373. Other prior art systems are Lego® Technic Sets 5118, 7471, 8002, 8074, 8412, 8437, 8440, 8444, 8445, 8457, 8479, 8482, 8483, 8485, 8828, 8836, 8839, 8856, and 9748.
As shown in FIG. 1A, an end P1 is connected to a bendable plastic rod P2 via neck P3. Front end P1, rod P2, and neck P3 are shaped to be received in a complementary slot P11-P13 of the receiver block P10. Thus, a plastic rod P2 with necks P3 and ends P1 disposed on either terminus of the rod P2 is used to tether blocks to which receiver block P10 may couple, provided the necks P3 and ends P1 are capable of receipt in the receiver block slots P11-P13. In an alternative arrangement shown by FIG. 1B, a receiver block P10 is comprised of a jaw P5, a mouth P6, and a tooth P7 that engages a recess/neck P3 in a plastic rod P2 received within block P10. In this arrangement, the prior art receiver block P10 relies on plastic-on-plastic coupling between tooth P7 and recess P3 to maintain rod P2 in the block P10, e.g., a crimping connection.
All of these linkage systems suffer disadvantages in terms of the reduction in strength from repeated use and/or exposure to heat, weakness when loaded in a direction perpendicular to their cross-section, and/or lack of ability to be bent in any number of conformations while also substantially maintaining a conformation in three-dimensional space, e.g., wilting or buckling in response to loads.

SUMMARY OF THE INVENTION

A building block system for interconnecting Lego® and non-Lego® like bricks together via use of at least a bendable metal component that has posability with and without a coating disposed on the metal surface.
By having posability, a linkage may have an unlimited range of displacement in three-dimensional space and be able to hold its conformation in loaded and/or unloaded configurations. Such a linkage may serve as a universal joint for building blocks.
The posable linkage may be coupled to a building block using one or more of the following: the building block apertures themselves, a combination of the building block apertures and intermediary components within the building block, and/or a socket or adaptor disposed within the building block either alone or in combination with other features of the building block.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate the prior art and have been previously described.

FIG. 2 illustrates an exemplary embodiment of one form of exemplary inventive building block linkage system.

FIGS. 3A-D illustrate exemplary embodiments of exemplary building block linkages for an exemplary inventive building block linkage system and assembly method.

FIGS. 4A-G illustrate other exemplary embodiments of other forms of exemplary inventive building block linkage systems and assembly methods.

FIG. 4H illustrates an exemplary socket loading technique for exemplary inventive building block linkage systems.

FIGS. 5, 6A-B, and 7A-F illustrate other exemplary embodiments of other forms of exemplary inventive building block linkage systems and assembly methods.

FIGS. 8 and 8A-B illustrate views of an exemplary anchor block for various forms of exemplary inventive building block linkage systems and assembly methods.

FIGS. 9A and 9B illustrate still another exemplary embodiment of other forms of exemplary inventive building block linkage systems and assembly methods.

FIGS. 10A-C, 11A-C, 12A-C, and 13A-C illustrate other exemplary embodiments of anchor blocks and linkages used in forms of an exemplary inventive building block systems and assembly methods.

FIGS. 14A-D illustrate other exemplary embodiments of adaptors for exemplary blocks and linkages used in other forms of an exemplary inventive building block systems and assembly methods.

FIG. 15 illustrates an exemplary embodiment of an exemplary inventive building block system.

FIGS. 16A-D illustrate exemplary embodiments of linkages.

FIG. 17 illustrates an exemplary embodiment of an exemplary method of manufacture of an exemplary posable linkage.

FIGS. 18A-D illustrate other exemplary embodiments of an exemplary inventive building block system.

FIGS. 19A-D illustrate still further exemplary embodiments of an exemplary inventive building block system.

In the drawings like characters of reference indicate corresponding parts in the different figures. The drawing figures, elements and other depictions should be understood as being interchangeable and may be combined in any like manner in accordance with the disclosures and objectives recited herein.

DETAILED DESCRIPTION

With respect to FIG. 2, an exemplary linkage 2 may be configured to fit within an opening 5 of a receiving exemplary building block 10 (hereinafter referred to as block or brick 10, which may be a Lego-like brick). An exemplary brick 10 may be made of plastic, rubber, or metal, but preferably PLA or Acrylonitrile Butadiene Styrene (ABS) plastic. An exemplary brick 10 may be prismatic, cubic, spherical, conical, pyramidal, or any other form of polyhedron in shape. When assembled, the head 1 and tail 0 of an exemplary linkage 2 may be located within a cavity 9 of exemplary block 10. In an exemplary embodiment, head 1 of an exemplary linkage 2 need not enter the exit 6 of exemplary block 10. The opening 5 and exit 6 of an exemplary block 10 may also serve as adaptors for connecting exemplary block 10 to other building blocks. For example, in an exemplary Lego® block 10 opening 5 may be sized to fit within the exit 6 of another exemplary building block (not shown). Conversely, an exit 6 of an exemplary Lego® block 10 may be sized to fit about an opening 5 of another exemplary building block. According to these embodiments, the engagement between an exemplary linkage 2 and exemplary block 10 may be considered a joint 20.
In one embodiment, an exemplary linkage 2 is made of a metal and is flexible yet posable. An example of posability may be that an exemplary linkage 2 can be bent into any conformation, without any limit on degrees of freedom of movement, and substantially maintain that conformation in three-dimensional space. As another example of posability, an exemplary linkage 2 may be configured to dispose at least two blocks 10, which are adapted to receive an exemplary linkage 2, in different positions in three-dimensional space and substantially maintain those positions over time without the need for any other movable parts but the linkage 2. Accordingly, an exemplary linkage 2 may be the exclusive means of positioning exemplary building blocks which it interconnects. As such, an exemplary linkage 2 may allow exemplary building blocks to be translated, rotated, and/or held in positions with respect to one another in three-dimensional space. Further alternatively, an exemplary linkage 2 may couple a plurality of different block systems together, e.g., a Lego® block to a K'nex piece.
In another embodiment, an exemplary linkage 2 may have one or more of the following exemplary characteristics: (i) a wire-like shape; (ii) made out of one or more of the following and/or their combinations and/or galvanized variants: aluminum, copper, iron, or brass; (iii) dimensioned so that it can be received within an opening 5 and/or an exit 6 of an exemplary block 10; (iv) dimensioned so that it can be received within fabric, flexible plastic, or elastomer tubing; (v) dimensioned so that its diameter is within the range of diameters between those of opening 5 and those of exit 6 of an exemplary block 10; (vi) a diameter of approximately 0.123 inches to approximately 0.193 inches; (vii) be approximately 5- to approximately 8-gauge wire; or (viii) be an armature wire. In an exemplary embodiment, an exemplary linkage 2 is about 0.12574 inches in diameter and is made from a flexible aluminum armature wire. While an exemplary linkage 2 may preferably be circular in cross-section, any number of cross-sections of an exemplary linkage 2 may be contemplated depending on the exemplary brick with which it couples.
For example, an exemplary linkage 2 may be configured so that it and/or its head 1 or tail 0 may friction-fit within an exemplary block 10 opening 5, exit 6, and/or other such aperture as described herein, provided the exemplary block 10 material creating the cross-section of such opening 5, exit 6, and/or other such aperture does not go beyond its modulus of resilience (e.g., the cross-section may be the same as or smaller than the cross-section of an exemplary linkage 2, head 1, and/or tail 0). Where multiple cross-sections are involved, an average cross-section may be used to determine the applicable modulus of resilience. An average cross-section of an exemplary linkage 2 may be the cross-section at one end of linkage 2 to the point on linkage 2 just before where the cross-section remains substantially un-changed along the length of linkage 2. An average cross-section may be utilized for determining the average cross-section of an aperture in exemplary block 10, e.g., measuring the cross-section from the opening 5 or exit 6, whichever is closest to the cross-section of the aperture surface most distal to the beginning measuring point whether it be opening 5 or exit 6 as the case may be.
An exemplary linkage 2 may be included in and made out of any other material or combination of materials that results in properties equivalent to those achieved by structures with one or more of the foregoing characteristics and posabilities. For example, a metal wire may be included within an elastomer tube so that the combination of the two, which together form an exemplary linkage 2, may have the flexibility and posability of the underlying metal wire (for example the illustrative embodiments and related disclosures of FIGS. 16A-D). Those skilled in the material arts may be able to identify other materials of which a single exemplary linkage 2 can be made to achieve one or more of the foregoing requirements of the metal linkage 2 embodiments, such as, polymers and plastics, provided the final composition has posability.
An exemplary linkage 2 may have a plurality of orientations in three-dimensional space in which it may position blocks coupled thereto. In the illustrative embodiment of FIG. 2, any number of different points in three-dimensional space, identified by Cartesian coordinates (x, y, z), may be found about the length of a single exemplary linkage 2. For example, point “A” on an exemplary linkage 2 has exemplary coordinates (0, 0, 0), meaning that this portion of exemplary linkage 2 may serve as an origin position or point of comparison. Point “B”, which has coordinates (−1, 1, −1), may suggest that this part of linkage 2 is located in a plane behind and above Point “A” in three-dimensional space. Point “C”, which has coordinates (1.5, −0.5, 1), may suggest that this part of an exemplary linkage 2 is in a plane ahead of and under point “A.” Thus, each of the blocks coupled to exemplary linkage 2 as shown in FIG. 2 are oriented and positioned in different parts of three-dimensional space. Further, an exemplary linkage 2 may be configured so that the positioning of the blocks coupled thereto in the three-dimensional space is substantially maintained. Because of its flexibility, an exemplary linkage 2 may also be configured so that its parts have different positions in three-dimensional space as bricks are displaced from one position to another. Further orientation arrangements capable with an exemplary linkage 2 may also be understood with reference to FIGS. 11C, 15, 18B-D, and their related, interrelated, and interchangeable disclosures.
With reference to FIGS. 3A-D, exemplary linkages 2 may be shown with different heads 1. For ease of reference, head 1 may be considered the portion of an exemplary linkage 2 that may be used to join an exemplary linkage 2 to exemplary bricks 10, although tail 0 may have the same or similar purpose for the same or different bricks 10. Thus, head 1 has no restrictive beginning point, but may comprise one end of an exemplary linkage 2. Likewise, tail 0 has no restrictive beginning point, but may comprise the other end of an exemplary linkage 2 opposite head 1. In an exemplary linkage 2 of the wire-type, such linkage may have a head 1 and a tail 0 at either end. While an exemplary linkage 2 has thus far been described in such manner, the inventive system may utilize linkages 2 made up of multiple heads 1/tails 0 depending on design purposes, e.g., linkages with “Y” shapes, “X” shapes, cruciform, and others. Unless otherwise indicated, embodiments showing only one head 1 or tail 0 of an exemplary linkage 2 do not foreclose the existence of any number of heads 1, tails 0, and linkage 2 types previously described. Additionally, while a head 1 or tail 0 may be used to illustrate an embodiment and describe it, it should be understood that descriptions of one may apply equally to the other.
An exemplary linkage 2 may be shown in FIG. 3A as having a head 1 comprised of a conical or spherical terminus 11 and one or more threads or windings 12. While shaped in this fashion, terminus 11 may be flat, concave, or any other surface. In another exemplary embodiment illustrated by FIGS. 3B and 3C, an exemplary linkage 2 may have a head 1 comprised of bumps or curved recesses 3 about the linkage's circumference and/or perimeter. In yet another exemplary embodiment, which may be illustrated by FIG. 3D, an exemplary linkage 2 may have a head 1 comprised of one or more discs 3 a separated by one or more recesses 3. The head 1 of an exemplary linkage 2 may comprise one or more of the aforementioned and other surface features for the purposes of serving as part of an exemplary system described herein. Such contours may be made by 3D printing, laser machining, laser sintering, CNC machining, lathes, molding, extrusions, taps, and/or dies.
The illustrative embodiment of FIG. 4A may show parts of an exemplary inventive system. According to this illustrative embodiment, an exemplary linkage 2 may have a head 1 comprised of round surfaces 3. An exemplary linkage 2 in FIG. 4A may be received within exemplary brick 10 through opening 5. In this illustrative embodiment, exemplary brick 10 may be hollow inside so that it may have a cavity 9 with inner surface 8 and an outer surface 7. Disposed within cavity 9 of exemplary brick 10 may be an exemplary socket 15.
According to one aspect of an inventive system, an exemplary socket 15 may be sized, shaped, and/or contoured to fit partially or completely within cavity 9, e.g., as a prismatic, spherical, or other polyhedron shape, in order to receive and hold a head 1 or tail 0 of an exemplary linkage 2. For example, an exemplary socket 15 may be such that it does not inhibit the use of opening 5 or exit 6 to allow exemplary brick 10 to combine with other building blocks. Alternatively, an exemplary socket 15 may be contoured so that when placed within an exemplary brick 10, it may have recesses sized and shaped like an exemplary opening 5 or exit 6 to allow exemplary brick 10 to combine with other bricks. In an exemplary embodiment, an exemplary socket 15 may be a component of an exemplary inventive system that may be placed within exemplary brick 10 so as not to disturb its uses and functions for assembly with other building blocks.
As shown in FIG. 4A, an exemplary socket 15 may comprise a channel 16 into which an exemplary linkage 2 may be received. Channel 16 may be sized and shaped to complement head 1 of linkage 2 when received within an exemplary socket 15. Alternatively, channel 16 may be sized and shaped so that head 1 of linkage 2 friction-fits within an exemplary socket 15. For example, as shown in FIG. 4B, an exemplary inventive system 20 may have a linkage 2 with a head 1 comprised of a plurality of spherical surfaces 3. When inserted into exemplary brick 10 containing an exemplary socket 15, spherical surfaces 3 compress walls of cylindrical channel 16 while walls of channel 16 press against spherical surfaces 3. In this manner, channel 16 may be molded so that compression surfaces 15 a hold or brace the head 1 of linkage 2 so as to maintain its reception in an exemplary socket 15 and thereby retention in exemplary brick 10. According to another exemplary embodiment, channel 16 may be sized and shaped for bracing an exemplary linkage 2 but allow passage of other exemplary building blocks known to those skilled in the art, e.g., as may be illustrated in FIGS. 5 and 14D.
In an exemplary embodiment, channel 16 may possess an average cross-section (as measured from its furthest depth to its terminus at the surface of an exemplary socket 15) that is greater than 0% and up to about 15% smaller than the average cross-section of head 1 or tail 0 of an exemplary linkage 2 (as measured from the end of linkage 2 to the terminus of the contours on either head 1 or tail 0). In an exemplary embodiment, channel 16 may be about 13% smaller in average cross-section compared to that of head 1 or tail 0 of linkage 2. Alternatively, a cross-section or average cross-section of channel 16 may be up to any percentage smaller than a cross-section or average cross-section of head 1 or tail 0 of linkage 2 so long as the introduction of such head 1 or tail 0 of linkage 2 does not cause an exemplary socket 15 to go beyond its modulus of resilience at a given temperature and hardness.
With reference to the illustrative embodiment of FIG. 4C, another exemplary socket 15 within exemplary brick 10 may have a contoured channel 16 having one or more grips 17 for gripping or bracing an exemplary linkage 2, which may have a head 1 comprising disks 3 a and recesses 3. As previously described with respect to channel 16, an exemplary contoured channel 16 may have the same characteristics, such as being complementary to the shape of head 1 or be slightly smaller to create a friction-fit by way of compression surfaces 15 a. In another exemplary embodiment, channel 16 may not be complementary to linkage 2 and/or head 1 so as to create more gripping, hugging, and/or bracing surfaces within channel 16.
As illustrated in the exemplary embodiment depicted in FIG. 4D, an exemplary joint 20 may comprise an exemplary linkage 2 with a head 1 comprised of alternating discs 3 a separated by recesses 3 braced by grips 17 in an exemplary socket 15. According to this exemplary embodiment, complimentary grips 17 and recesses 3 may result in a robust connection between linkage 2 and exemplary brick 10. For example, where an exemplary socket 15 may be made of an elastomer material, a linkage 2 with a head 1 comprising alternating discs 3 a and recesses 3 may be pushed against the grips 17 of an exemplary socket 15 causing them to deflect distally from the direction of entry of the linkage 2. According to such an embodiment, an exemplary elastomer socket 15 with elastic grips 17 may allow the grips 17 to deflect back towards the direction of entry of linkage 2 after a linkage 2 contour passes such that they are substantially found between the linkage 2 contour (as illustrated, discs 3 a) and adjacent to the recesses 3 of the head 1. With respect to this embodiment, the elasticity of grips 17 may allow them to permit entry of head 1 of linkage 2 when inserted into the socket 15 while substantially resisting departure of head 1 from an exemplary socket 15 if linkage 2 experiences forces tending to displace it from an exemplary socket 15, e.g., tension forces.
In an alternative embodiment illustrated with respect to FIGS. 4F and 4G, grips 17 may be modified to allow easier displacement from an exemplary socket 15 (e.g., sloped grips 17 a) and/or discs 3 a may be modified to allow head 1 of an exemplary linkage 2 to more easily displace from gripping socket (e.g., bowl discs 3 b).
In another exemplary embodiment illustrated by FIG. 4E, an exemplary brick 10 may have a crevice 8 a in inner surface 8. An exemplary crevice 8 a may be of any cross-section and may span partially or fully about inner surface 8, including about the circumference of inner surface 8, in an intermittent arrangement about inner surface 8, and/or in a continuous/discontinuous spiral pattern. Preferably, crevice 8 a may be located between opening 5 and exit 6 of exemplary brick 10. Preferably, crevice 8 a may be only within cavity 9. Alternatively, an exemplary crevice 8 a may be a through-hole 7 a connecting inner surface 8 to outer surface 7. As will be further described, a through-hole crevice 8 a may be useful for selective operation of system 20.
Further illustrated in the illustrative embodiment of FIG. 4F may be an exemplary socket 15 having wings 15 a. Exemplary wings 15 a may be configured to be received within an exemplary crevice 8 a within exemplary brick 10. While wings 15 a may be shown as single extensions from the circumference of a circular socket 15, they may also be shaped to spiral about the outer surface of an exemplary socket 15 so that when met with complementary spiral crevice 8 a, such a socket 15 may be screwed into exemplary brick 10. Accordingly, an exemplary interaction between crevice 8 a and wings 15 a may further increase the bracing capability of an exemplary socket 15 in an exemplary joint 20.
As previously described with respect to a through-hole crevice 8 a, reception of an exemplary socket 15 within an exemplary brick 10 with such a through-hole 7 a, such as may be illustrated with respect to FIG. 4E, may possess the added advantage of being released from exemplary brick 10 by inserting a pin or pencil point into through-hole 7 a to depress wing 15 located in the through-hole crevice 8 a. In so doing, an exemplary socket 15 may be released from cavity 9. Crevice 8 a and wings 15 a may be complementarily shaped and/or sized to increase friction there between, e.g., crevice 8 a may be triangular in cross-section while wings 15 a were circular or rectangular. An exemplary brick 10 possesses one crevice 8 a that is substantially spherical in shape while an exemplary socket 15 may have one wing 15 a that is substantially spherical in shape. Other varieties and combinations may be configured for particular needs.
As illustrated in FIGS. 4A-G, an illustrative inventive system 20 may be such to reduce the propensity of an exemplary linkage 2 from disengaging from exemplary brick 10 by way of an exemplary socket 15. An exemplary socket 15 may be made of polymer, and more particularly, an elastomer material or thermoplastic, preferably an elastomer such as rubber or silicone. As an elastomer, an exemplary socket 15 may be advantageously suited for insertion in exemplary brick 10 by way of a calendaring process 102 shown in FIG. 4H. While other forms of calendaring processes may be understood to those skilled in the art, the exemplary calendaring process illustrated diagrammatically in FIG. 4H may show calendaring wheels C compressing elastomer socket 15 so as to fit within exit 6 of an exemplary brick 10.
With reference to the illustrative embodiment of FIG. 5, an exemplary linkage 2 may be comprised of a head 1 for reception within a channel 16 as well as intermediary ribs 3 c/3 d extending from its own surface structures, which may be the same as or different from those on head 1 and proximal or distal to the same, for reception in a separate channel 16 a of a separate socket 15 in a separate exemplary brick 10. For example, an exemplary linkage 2 may have a head 1 comprising recesses 3 and fins 3 a. The same exemplary linkage 2 according to this illustrative embodiment may have grooves 3 c with extensions 3 d. A first exemplary brick 10 ₁may be coupled to head 1 of an exemplary linkage 2 by way of an exemplary socket 15 such that linkage 2 does not pass from exemplary brick 10 ₁ opening 5 to exit 6 via channel 16. Grooves 3 c and extensions 3 d may also friction fit a second exemplary brick 10 ₂by way of a second through-socket 15 ₁whose through channel 16 a allows full passage of an exemplary linkage 2 from opening 5 to exit 6 of the exemplary brick 10 ₂. Alternatively, one or more exemplary bricks 10 ₃may comprise channels 16 b that slidingly or frictionally engage the non-contoured surface of an exemplary linkage 2. Alternatively, exemplary bricks 10 ₃may also slidingly or frictionally engage both contoured and non-contoured surfaces of an exemplary linkage 2. While exemplary brick 10 ₃may be illustrated as a small exemplary brick, e.g., a 1×1 Lego® plate, exemplary brick 10 ₃may be any size and shape with a channel 16 b through its surfaces.
An exemplary multi-surface linkage 2 may be able to interact with numerous exemplary bricks 10 _n(where n is any integer) to provide building points for other exemplary blocks, e.g., exemplary building blocks 100, on its posable surface. In other words, exemplary bricks 10 ₂may be anchored by surface structures intermediary of linkage 2's head 1 and tail 0, e.g., exemplary block 10 ₃. While such exemplary bricks have been shown having a through socket 15 ₁other forms of exemplary bricks 10 ₂and 10 ₃, with and without an exemplary socket 15 that permit full passage of an exemplary linkage 2 there through, are also suitable. Thus, an exemplary linkage 2 may act as the foundation for building numerous block structures on its flexible surfaces and may serve as a universal scaffolding for exemplary building block assemblies 100.
With reference to the illustrative embodiments of FIGS. 6A-B, an exemplary brick 10 may contain an exemplary socket 15 comprising a channel 16 having spiral threads 18 for complementary screw-threads 12 corresponding to head 1, tail 0, and/or terminus 11 of an exemplary screw linkage 2. As illustrated in these illustrative embodiments and may be used in others, an exemplary socket 15 may possess rounded surfaces 15 c to reduce material usage and cost of fabrication. Alternatively, rounded surface 15 c may take the form of a funnel-like structure adjacent an opening 5 or exit 6 to facilitate reception of an exemplary linkage 2 within the channel 16. An exemplary socket 15 may also be porous or sponge-like in material composition. While terminus 11 of exemplary screw linkage 2 may be pointed or conical, terminus 11 of an exemplary screw linkage 2 may be substantially flat, e.g., like the terminus 11 of linkage 2 in FIG. 7B.
As illustrated in FIG. 6B, screw threads 12 on the head 1 or tail 0 of an exemplary linkage 2 may be similar to a screw or other threaded fastener known to those skilled in the art. Likewise, threads 18 may be complementary to such screw threads 12 to allow for a robust connection between screw linkage 2 and exemplary screw socket 15. Alternatively, an exemplary screw linkage 2 with threads 12 may be used with sockets 15 without threads 18 and rely on the modulus of resilience of an exemplary socket 15 to brace such screw linkage 2 threads. One advantage of using an exemplary screw socket 15 in the aforementioned embodiments may be to establish a greater amount of surface contacts between screw linkage 2 and its thread surfaces 12 and an exemplary socket 15. Combining the various retention features described, e.g., grips 17 and/or screw channel 16, in one exemplary socket 15 may provide additional linkage 2 retention properties and advantages. For example, for an exemplary linkage 2 with a screw head 1 with threads 12 and a recess 3 distal of the threads 12, one may provide an exemplary socket 15 having a grip 17 proximal to the entry of the channel 16 and screw threads 18 distal from the entry so that the exemplary screw linkage 2 may both screw into an exemplary socket 15 and be restrained from movement by grip 17.
As illustrated in FIG. 7A, an exemplary brick 10 may be solid except for opening 5 in which a channel 16 with threaded wall 18 may be found and an exit 6 for receipt of an adjoining exemplary brick 10. Exemplary screw linkage 2 may then screw into exemplary brick 10 as shown in FIG. 7B. According to the illustrative embodiment of FIG. 7B, an exemplary screw linkage 2 may be received within screw channel 16 and screwed into threaded wall 18 using its threads 12 extending from the head 1 and/or tail 0 of screw linkage 2. The shape and/or dimensions of screw channel 16 may be based on the needs and loads of screw linkage 2. Alternatively, the shape and/or dimensions of screw channel 16 may be contingent on the shape and/or dimensions of exemplary brick 10. For example, screw channel 16 may be located adjacent to threads 18 found on opening 5 and/or exit 6. In an exemplary embodiment, exemplary brick 10 with screw channel 16 may be capable of assembly to other bricks (not shown) using the geometries of opening 5 and exit 6 even though it may have a screw channel 16 embedded therein or threads 18 on the inside of opening 5 and/or exit 6. This is the same for the other embodiments having a screw channel 16 in a socket 15.
Screw channel 16 may be made by boring out an exemplary brick 10 and using a tap and die to create the threads 18 of the channel for an exemplary screw linkage 2. Alternatively, a lathe may be utilized. Further alternatively, as disclosed herein, exemplary brick 10 containing a screw channel may be made using 3D printing technologies known to those skilled in the art.
In another exemplary embodiment illustrated by FIG. 7B, exemplary screw linkage 2 may be received within the material of exemplary brick 10. According to such embodiments, exemplary brick 10 may have an opening 5, exit 6, a cavity 9, and a screw channel 16 disposed between opening 5 and cavity 9 or between exit 6 and cavity 9. The screw channel 16 may be the only channel with threads 18 for interaction with threads 12 of terminus 11 of screw linkage 2. Alternatively, threads 18 may be found within opening 5 or exit 6 of an exemplary brick 10 and optionally may require an additional screw channel 16. The extension of threads beyond screw channel 16 to opening 5 and/or exit 6 may be provided for in any of the other disclosed embodiments involving screw linkages 2. According to the alternative embodiment where only opening 5 and/or exit 6 possess threads 18 may reduce the amount of threading required in exemplary brick 10 and/or an exemplary socket 15.
Other exemplary screw bricks 10 may be illustrated by way of FIGS. 7C-E. For example, an illustrative embodiment of an exemplary screw brick 10 as shown in FIG. 7C may not have an opening 5 but may have a screw channel 16, an exit 6, and a space 9 for assembly to other bricks (not shown). Alternatively, an exemplary screw brick 10 may only have a screw channel 16 and no other structures. In the illustrative embodiment of FIG. 7D, an exemplary screw brick 10 may have a plurality of screw channels 16 of various sizes, threading, and orientations. As illustrated, exemplary screw brick 10 of FIG. 7D may comprise one type of screw channel 16 p and 16 q, and another type of screw channel 16 r in various sides of exemplary brick 10. According to this illustrative embodiment, an exemplary multi-screw port brick 10 may permit numerous flexible linkages 2 to extend therefrom. While exemplary brick 10 may be illustrated as rectilinear, there is no requirement that exemplary brick 10 need be so. When an exemplary brick 10 may comprise one or more screw channel 16 s about a spherical surface, such an exemplary brick 10 may allow for multiple screw linkages 2 disposed in various planes in three-dimensional space at one time, e.g., FIG. 7E.
While screw channels 16 p/16 q/16 r are oriented at 90 degrees, such screw channels do not need to be orthogonal to one another but may have more acute and/or obtuse angles with respect to one another. An exemplar of an exemplary brick 10 having an angled screw channel 16 may be understood with respect to FIG. 7E. An exemplary brick 10 may have one or more angled screw channels 16 s/16 t within its surfaces, including in corners or on other points of the exemplary brick 10 surface.
In another exemplary embodiment illustrated by FIG. 7E, an exemplary brick 10 may have a hybrid of rectilinear, rounded or spherical or hemispherical surfaces into which screw channel 16 s may be disposed. In such embodiments, an exemplary screw linkage 2 may be oriented in a plane other than one orthogonal to the surface on which exemplary brick 10 may sit, e.g., where exemplary brick 10 assembles to other bricks (not shown), screw channel 16 may be oriented at less than 90 degrees from the exemplary brick-to-brick assembly surface. Similarly, in other exemplary embodiments, a plurality of screw channels 16 may be disposed on an exemplary brick 10 so that they are both oriented with respect to one another and exemplary brick 10 at non-orthogonal positions and/or less than 90 degrees from any exemplary brick-to-brick assembly surface.
As described, an illustrative exemplary hybrid block 50 may be composed using 3D printing or other formation methods known to those skilled in the art. As illustrated in FIG. 7F, an exemplary hybrid building block 50 may comprise an exemplary socket 15 located in a cavity 9 between a screw channel 18 and opening 5. As illustrated, cavity 9 may hold an exemplary socket 15 having surface contours, such as grips 17, for gripping recesses 3 of an exemplary linkage 2. Accordingly, such an exemplary hybrid block 50 may allow an exemplary screw linkage 2 having threads 12 and recesses 3 about its length to have a plurality of coupling regions within exemplary block 50. In the illustrative embodiment of FIG. 7F, an exemplary linkage 2 may screw into exemplary block 50 while also being gripped by grips 17 of an exemplary socket 15. As illustrated, an exemplary socket 15 may act as a diaphragm or friction washer for an exemplary building block system joint 20. Any variety and order of linkage recesses 3, threads 12, and surfaces 3 a-g, as described elsewhere, may be used up and down an exemplary linkage 2. As such, exemplary hybrid block 50 may have numerous sockets 15 and receiving cavities 9, with and without contours, e.g., threads 18, and in any order to accommodate a particular exemplary linkage 2 and/or add to retention of such linkage 2.
With reference to the illustrative embodiments of FIGS. 8, 8A-B, 9A-B, 10A-C, and 11A-C, an exemplary clamshell-type brick 30 (hereinafter referred to as “brick 30”) may comprise a plurality of exemplary brick portions, for example, 10 a and 10 b, with inner surfaces 8 a and 8 b, respectively, coupled via flexible portion 31. Flexible portion 31 may be a piece of material of the same or different composition of other parts of exemplary brick 30. In one exemplary embodiment, exemplary brick 30 may be made from a polymer, such as an acrylic, while flexible portion 31 may be comprised of a more malleable polymer. In an exemplary embodiment, flexible portion 31 may be capable of allowing exemplary brick 30 to open and close so that portions 10 a and 10 b abut one another so that surfaces 8 a and 8 b and outer surface 7 are substantially continuous. According to other illustrative embodiments, flexible portion 31 may be configured to allow exemplary brick 30 to open and close like a clam shell so that, when closed, substantially no gaps exist in one or more of outer surface 7, inner surfaces 8 a and 8 b, opening 5, or exit 6. While the illustrative embodiment of FIGS. 8, 8A-8B illustrate one flexible portion 31 in the longitudinal direction, numerous other flexible portions 31 may be found longitudinally about exemplary brick 30 to allow opening and closing of the same.
As further illustrated by the illustrative embodiment of FIG. 8, an exemplary brick 30 may be opened about flexible portion 31 such that two inner surfaces 8 a and 8 b for two halves 10 a and 10 b, respectively, are visible when viewing exemplary brick 30. Teeth 32 a and 32 b extend outwardly from the inner surfaces 8 a and 8 b, respectively. While teeth 32 a/32 b have been shown with rectangular cross-sections, any shape may be suitable for use for the construction of teeth 32 a/32 b. A view of an exemplary cross-section made by line A-A in FIG. 8 may be illustrated in FIG. 8A. As shown, the opening 5 of exemplary brick 30 may be opened about flexible portion 31 exposing teeth 32 a/32 b and the upper surfaces 7 of halves 10 a and 10 b.
A view of an exemplary cross-section made by line B-B in FIG. 8 may be illustrated by FIG. 8B. As illustrated, an exemplary brick 30 may be opened so that teeth 32 a/32 b are exposed for the exemplary brick 30 halves, 10 a and 10 b, respectively. Again, these halves 10 a/10 b open about flexible portion 31. FIG. 9A illustrates an exemplary operation of an exemplary brick 30. In the illustrative embodiment of FIG. 9A, an exemplary linkage 2 with recesses 3 and fins 3 a at head 1 may be configured to receive a complimentarily shaped tooth 32 a/32 b. Accordingly, the toothed exemplary clam brick 30 illustrated in these embodiments may be used to lock in place an exemplary linkage 2 having a properly configured head 1 based on the surface structure of an exemplary linkage 2 and the inner surface 8 a/8 b structures of exemplary clam brick 30.
In another exemplary embodiment, exemplary brick 30 may be able to retain an exemplary linkage 2 with or without additional supports. In the former scenario, a hollow exemplary cap brick 40 may be used in which a hole sized to fit an exemplary linkage 2 slides down linkage 2 to the juncture between linkage 2 head 1 and exemplary clam brick 30. An exemplary cap brick 40 may have a peg portion 41, a ridge portion 43, a through-hole 44, and a receiver portion 42 for reception with other exemplary bricks 10/30/40/50/60/70/100. According to the illustrative embodiment of FIG. 9A, an exemplary cap brick 40 receiver portion 42 may receive within itself the opening 5 of exemplary clam brick 30. Accordingly, exemplary cap brick 40 may preclude exemplary clam brick 30 from opening by virtue of its holding the opening 5 of exemplary clam brick 30 together, as may be understood with respect to FIG. 9B. Further exemplary bricks (not shown), may be attached to the peg portion 41 as needed. Exemplary cap brick 40 may take various other forms and sizes as needed and may be a portion of a building block that does not have a hollow passage for an exemplary linkage 2 there through, e.g., a 2×2 Lego® plate brick may have one stud that is an exemplary cap brick 40 and the remaining three studs or pegs as provided in the prior art.
In another exemplary embodiment of exemplary clam brick 30, as may be seen with reference to FIG. 10A, halves 10 a and 10 b may have on their inner surfaces 8 a and 8 b, respectively, a male receptor 33 a and a female receptor 33 b, each configured to couple to the other in a nested or overlapping arrangement. In use, an exemplary linkage 2 with a head hole 3 g in head 1 may be configured for reception within exemplary brick 30 and aligned with receptors 33 a/b so that when exemplary clam brick 30 closes, the receptors 33 a/b intersect within and/or through head hole 3 g of head 1 of an exemplary linkage 2. Accordingly, as illustrated in FIGS. 10B and 10C an exemplary linkage may be threaded by the receptors 33 a/b when exemplary clam brick 30 is closed. As may be further illustrated in FIG. 11A, any number or arrangement of receptors 33 a/b may be utilized for the particular purpose. As previously stated, receptors 33 a/b may be any shape or configuration suitable for use as holding an exemplary linkage 2 received in the exemplary brick 30.
With respect to the illustrative embodiments of FIGS. 11A-C, an exemplary clam brick 30 may contain a groove 34 in outer surface 7 of its halves 10 a/b for receiving a brace 35 therein. As illustrated, an exemplary groove 34 may be of any type of cross-section for the purpose and brace 35 may be made out of any type of material capable of holding an exemplary brick 30 together. In an exemplary embodiment, groove 34 may be a rectangular cross-section configured so that when brace 35 is placed therein, the brace 35 and outer surface 7 of exemplary brick 30 are substantially aligned.
As illustrated in FIG. 11C, a brace 35, which may preferably be made of an elastomer, such as rubber, is shown as being wrapped tightly about exemplary brick 30 while an exemplary linkage 2 is free to move outside of exemplary brick 30. As another exemplary embodiment of the posability and universal orientation of an exemplary linkage 2 may be further illustrated in FIG. 11C.
As illustrated in FIG. 11C, an exemplary linkage 2 may exit an exemplary brick 30 at point “A.” An exemplary linkage 2 may be undulated at point “B” so that it enters point (0.5, 0.5, −0.5), which means that as this part of linkage 2 ascends and proceeds to the right, it also goes behind point “A.” Point “C,” at coordinates (1, 2, −0.75), illustrates that an exemplary linkage 2 may be further bent behind point “B” while gravitating upwardly and further ahead of point “A” in the horizontal plane. Further illustrating the universal positioning of an exemplary linkage 2, point “D” located at the terminus 11 of tail 0 (which is shown with spiraling threads 12 thereon) may have coordinates (−2, 4, 1) thereby showing that the tail 0 of an exemplary linkage 2 may be bent behind its origin point and brought forward of the origin, even though it began with bending behind the origin (as in points “B” and “C”). As described, an exemplary linkage 2 would be configured to maintain bricks coupled to either of its ends in this configuration in three-dimensional space. Alternatively, an exemplary linkage 2, by virtue of its flexibility, may be configured to change these illustrated coordinates when displacing bricks coupled to its ends.
With reference to FIGS. 12A-C and FIGS. 13A-C, an exemplary porous brick 60 may be one possessing multiple cavities/apertures in its construction. For example, with respect to the exemplary porous brick 60 illustrated in FIG. 12A, such exemplary brick 60 may have one or more openings 5 extending from its outer surface 7, a first cavity 9 leading to one or more exits 6 and additional cavities 9 a, and one or more inner surfaces 8 which may have one or more crevices 8 a. In an exemplary embodiment, exemplary porous brick 60 may be an Erling Lego-like brick.
An exemplary porous brick 60 may be further illustrated in FIG. 12A with views from the front, rear, and side of the exemplary brick 60. Other types of exemplary porous bricks 60 may be readily understood by persons skilled in the art and may be used in addition to the illustrative exemplary porous brick 60 described. One or more of the openings 5 of an exemplary porous brick 60 may be configured to receive an exemplary linkage 2 therein.
In another embodiment in accordance with the illustrative features of FIG. 12B, an exemplary porous brick 60 may receive within its inner surface 8 an exemplary socket 15 adapted to fit within one of its cavities 9 so as to close off exit 6. In another embodiment, an exemplary socket 15 may have one or more wings 15 a configured to be received within a crevice 8 a in one of the cavities 9 of exemplary porous brick 60. An exemplary fitting of an exemplary socket 15 within exemplary porous brick 60 may provide a channel 16 through opening 5 for reception of an exemplary linkage 2 therein. According to the illustrative embodiment of FIG. 12B, an exemplary channel 16 may be a contoured channel 16 which may contain one or more grips 17. According to an exemplary method of use of an exemplary porous brick 60 with an exemplary socket 15, the first exemplary step may be to align an exemplary socket 15 to be placed within a complementary inner surface 8 of an exemplary porous brick 60 cavity. The second exemplary step may be to align socket channel 16 with an opening in the exemplary porous brick 60. The third exemplary step may be to use an exemplary linkage 2 head 1 to engage the combination of exemplary porous brick 60 and an exemplary socket 15 through an opening 5. The fourth exemplary step may be to couple exemplary porous brick 60 to adjacent exemplary bricks to preclude the disposition of an exemplary socket 15 from within exemplary porous brick 60 while in use. According to an exemplary embodiment, the third and fourth exemplary steps may be had in either order depending on needs. Further, while a contoured channel 16 may be shown, any other channels 16 (e.g., screw channels) may be contemplated as well as contoured openings 5 and/or exits 6 of such exemplary bricks 60 as per other embodiments.
With reference to FIG. 12C, an exemplary porous brick 60 alone or in combination with an exemplary socket 15 may be connected to an exemplary brick assembly 100 in which its cavity 9 where an exemplary linkage 2 may be received is closed off by surrounding exemplary bricks in the exemplary brick assembly 100. Exemplary brick assembly 100 may be comprised of one or more bricks compatible with exemplary porous brick 60 and receptive to its attachment and/or connection. As shown in the illustrative embodiment of FIG. 12C, an exemplary linkage 2 may be received through opening 5 of exemplary porous brick 60, which houses an exemplary socket 15 within its cavity 9, and is juxtaposed by exemplary brick assembly 100 such that an exemplary socket 15 is substantially confined within exemplary porous brick 60. According to this exemplary embodiment, an exemplary linkage 2 may have a contoured head 1. In an exemplary embodiment, which happens to be illustrated in FIG. 12C, recesses 3 and fins 3 a of head 1 interact with grips 17 of contoured channel 16 of an exemplary socket 15 to substantially retain an exemplary linkage 2 within exemplary porous brick 60.
In one aspect of the illustrative embodiments of FIGS. 12A-C, an exemplary porous brick 60 may have the added benefit of ease of removal of an exemplary linkage 2 from an exemplary socket 15. One exemplary illustration of such benefits may be shown with respect to FIGS. 13A-C. As shown in the exemplary illustrative embodiment of FIG. 13A, an exemplary linkage 2 may be used to expel an exemplary socket 15 out of a cavity 9 in exemplary porous brick 60. In one view, the cross-section of an exemplary socket 15, shown as socket 15 y, shows engagement of head 1 of an exemplary linkage 2 by one or more surface contours, such as fins 3 a and recesses 3, although others are contemplated and may be understood to those skilled in the art. As shown in FIG. 13A, the cross-sectional view of an exemplary linkage 2 socket channel 16 y illustrates an exemplary engagement with head 1 of an exemplary linkage 2, as disclosed.
FIG. 13B illustrates a view of the exemplary porous brick 60, an exemplary socket 15, and exemplary linkage 2 arrangements in another aspect of operation. According to the illustrative embodiment of FIG. 13B, while still engaged within an exemplary socket 15 and exemplary porous brick 60 but with an exemplary socket 15 expelled from exemplary porous brick 60, an exemplary linkage 2 may be rotated, e.g., within any 360 degree movement, but more preferably 180 degrees, within opening 5 such that the exemplary socket 15 may be turned (as shown by the arrow adjacent the letter “T”) in a different orientation, so that a side passage 16 x faces perpendicular to exemplary porous brick 60. Side passage 16 x may be a passage from either side of socket channel 16 by which socket 15 may be slidingly disengaged from head 1 of an exemplary linkage 2. In an exemplary embodiment, a portion 15 x of an exemplary socket 15 may be removed (as shown by the arrow adjacent the letter “R”) by slipping head 1 of an exemplary linkage 2 out of socket channel 16 by way of side passage 16 x, as may be illustrated by FIG. 13C.
Any disclosed socket 15 may have one or more side passages 16 x to allow an exemplary linkage 2 to disengage from an exemplary socket 15 in either exemplary porous bricks 60 or other exemplary bricks 10 as disclosed. Side passages 16 x may be used to allow users to switch different sockets 15 depending on needs, or allow for further materials and/or exemplary bricks 10/30/40/50/60/70 to be placed on an exemplary linkage 2 while constructing. Alternatively, slide passages 16 x embodiments of exemplary sockets 15 may be preferable for replacing sockets 15 after repeated use.
In the illustrative embodiments of FIGS. 14A, 14B, 14C and 14D, yet other mechanisms of linkage systems may be disclosed. For example, FIG. 14A shows an exemplary brick 70 with a passage 5/6 through its thickness for reception of parts much larger in diameter than exemplary linkage 2. Such exemplary bricks 70 may be found in Lego® Technic sets or other non-Lego® building block systems, e.g., K'nex. Exemplary bricks 70 may have surface contours 7 a, e.g., an indentation in surface 7, that surround or are adjacent to their passages 5/6. An exemplary contour 7 a may be an indentation in the surface 7 of exemplary brick 70.
As illustrated in FIG. 14B, an exemplary linkage 2 with a tail 0 may be placed within the cavity 9 of the exemplary brick 70 connected by passage 5/6. An adaptor socket 19 may possess an exemplary channel 16 configured as other disclosed channels of sockets 15 for reception of an exemplary linkage 2 therein. An exemplary adaptor socket 19 may possess one or more anchors 19 a substantially complementary to surface contours 7 a of exemplary brick 70. Exemplary anchors 19 a may take the form of lips, rims, or pegs, but may be any other structures that may serve to hold adaptor socket 19 within exemplary brick 70, either on surface contours 7 a of exemplary brick 70 or crevices 8 a in exemplary brick 70 (see FIG. 14C). Exemplary surface contours 7 a and crevices 8 a may be utilized within exemplary brick 70 to allow for friction fitting of adaptor socket 19 within the exemplary brick 70 cavity 9.
An exemplary adaptor socket 19 may be sized and shaped to fit within the cavity 9 of exemplary brick 70 so as to allow an exemplary linkage 2 to couple within exemplary brick 70 despite the fact that exemplary brick 70 may not normally hold an exemplary linkage 2 to keep it from moving or exiting the brick or block. This may be done by making adaptor socket 19 larger than the passage 5/6 of exemplary brick 70 to allow an exemplary adaptor socket 19 to friction fit within the cavity 9 of the exemplary brick 70. Alternatively, adaptor socket 19 may have surface contours 19 b, which may be any size and cross-section as needs may be, that when combined with crevices 8 a in exemplary brick 70 resist removal of the adaptor socket 19 while in use.
In an exemplary adapted brick 70 system illustrated by FIG. 14C, an exemplary linkage 2 may have its tail 0 within channel 16 of adaptor socket 19, much like an exemplary linkage 2 may fit within channel 16 of an exemplary socket 15. One or more crevices 8 a within cavity 9 of exemplary brick 70 may receive one or more adaptor surface contours 19 b. Adaptor socket 19 may have a solid portion that resists further displacement of an exemplary linkage 2 into channel 16. Alternatively, channel 16 of adaptor socket 19 may allow for complete passage of an exemplary linkage 2 there through, as illustrated by FIG. 14D. As illustrated in FIG. 14D, adaptor contours 19 b may be used to brace the surface contours 3 and/or 3 a of an exemplary linkage 2. Thus, an exemplary adaptor socket 19 and any of its various surface contours 19 b and anchors 19 a may function and be formed in the same manner as an exemplary socket 15 and its compression surfaces/wings 15 a, e.g., elastomer material and/or flexible material. Alternatively, an exemplary adaptor socket 19 may be made of a more rigid material that may be screwed or snapped into exemplary brick 70 by way of spiral contours 19 b coinciding with screw thread crevices 8 a within cavity 9 of exemplary brick 70. Other snap-to-fit arrangements of an exemplary adaptor socket 19 and exemplary brick 70 may be used as well to reduce tooling for an exemplary brick 70. An exemplary adaptor socket 19 may also be removed from an exemplary linkage 2 in similar manner to removal of an exemplary socket 15 as disclosed.
An example of an exemplary linkage 2 posability may be illustrated in FIG. 15. According to this illustrative embodiment, FIG. 15 may show the positioning of exemplary blocks 10 and 50 in three-dimensional space. As shown by the coordinates of points “A” and “B” of exemplary blocks 10 and 50, respectively, an exemplary linkage 2 may position the exemplary blocks and their adjoining assemblies 100 and 200, respectively, in different positions in three-dimensional space. These exemplary blocks may be further moved with respect to one another by virtue of the flexibility of an exemplary linkage 2. Exemplary linkage 2 may be disposed in various parts of three-dimensional space, as may be illustrated by FIG. 15, with reference to the coordinates of points “C” and “D” on sections of an exemplary linkage 2. According to this illustrative embodiment, the posability of an exemplary linkage 2 may substantially maintain the parts of an exemplary linkage 2 in their illustrated conformation, e.g., coordinates “C” and “D.” Further, the posability of an exemplary linkage 2 may substantially maintain exemplary blocks 10 and 50 (or other exemplary blocks 30/40/60/70) and their respective adjoining assemblies 100 and 200, respectively, at their coordinates “A” and “B,” respectively, over a span of time.
Those skilled in the art may understand various other methods and ways to secure an exemplary linkage 2 to an exemplary brick 10/30/40/50/60/70 using other techniques. Exemplary bricks 10/30/40/50/60/70 that may open or “lock” an exemplary head 1 of an exemplary linkage 2 may take various forms and variations, depending on the needs of the construction. They may involve exemplary bricks 10/30/40/50/60/70 with doors, clasps, or other moveable parts that allow an exemplary head 1 of an exemplary linkage 2 to enter and then resist exiting the exemplary brick 10/30/40/50/60/70.
For all exemplary embodiments, whether illustrated, described, or understood from combination from the disclosures herein, exemplary bricks 10/30/40/50/60/70, brace 35, and/or sockets 15/19 may be printed using 3D printers known to those skilled in the art, such as those made or used by MakerBot Industries LLC of Brooklyn, N.Y. (Replicator series), Mcor Technologies Ltd. of Co Louth, Ireland (Iris series and Matrix series), 3D Systems Corp. of South Hill, S.C. (ProJet series and CubePro series), Voxeljet AG of Friedberg, Germany (VX series and VXC series), The ExOne Company of North Huntington, Pa. (S-Max, S-Print, M-Print, M-Flex, X1-Lab, and Orion series), Arc Group Worldwide of DeLand, Fla., and Stratasys, Inc. of Eden Prairie, Minn. (Mojo, uPrint SE series, Objet series, Dimension, Fortus, and printers using FDM, WDM, and Polyjet technologies). Exemplary blocks or bricks 10/30/40/50/60/70, brace 35, and/or socket/adapter 15/19 may also be manufactured using extrusion, blow molding, casting, or other fabrication methods known to those skilled in the building block art. While an exemplary linkage 2 may also be 3D printed, it may also be machined from metal or equivalent materials, as described herein, using laser cutting and sintering, extrusion, stamping, or CNC machining.
In an exemplary embodiment, an exemplary socket 15 may be 3D printed within exemplary brick 10 while exemplary brick 10 is being formed. Alternatively, exemplary brick 10 may be 3D printed and socket 15 may be simultaneously 3D printed within exemplary brick 10 (e.g., an exemplary hybrid brick 50). 3D printing fabrication of an exemplary brick 10 and socket 15 subsystem may be particularly suited for mass production of such constructs and reduce the need for physical assembly of the two structures post-fabrication.
In an exemplary embodiment, an Objet260 and Objet500 Connex Multimaterial 3D printer manufactured by Stratasys, Inc. of Eden Prairie, Minn. or a ProJet 5500X manufactured by 3D Systems Corp. of South Hill, S.C. may form exemplary brick 10/30/40/50/60/70 using one material while also using another material for the socket 15, thereby reducing the assembly process and increasing the likelihood of precise fitting between the socket 15 and exemplary brick 10. Any and all embodiments described herein may be formed by such simultaneous 3D printing processes known to those skilled in the building block art (e.g., exemplary hybrid blocks 50).
In an exemplary embodiment, an exemplary socket 15 may be 3D printed within exemplary brick 10 while exemplary brick 10 is being formed. Alternatively, exemplary brick 10 may be 3D printed and socket 15 may be simultaneously 3D printed within exemplary brick 10 (e.g., an exemplary hybrid brick 50). 3D printing fabrication of an exemplary brick 10 and socket 15 subsystem may be particularly suited for mass production of such constructs and reduce the need for physical assembly of the two structures post-fabrication.
In an exemplary embodiment, an exemplary posable linkage 2 may be fabricated to comply with the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing, which is incorporated herein by reference in its entirety. In one embodiment, exemplary posable linkage 2 will satisfy one or more of subsections of section 9.2 and all of section 18, in particular, section 9.2.4 Sharp Point Test, 9.2.5 Sharp Edge Test, and 9.3.6 Flexure Test of the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing.
As further illustrated in the exemplary embodiments of FIGS. 16A-D, an exemplary linkage 2 may contain a component 2A of diameter D_Mand a coating or cover 2B of thickness T_C. The cover or coating 2B may be one or more of the covers, coatings, and/or tubings described herein and may be removable or permanently attached to component 2A. Component 2A may be made of a flexible metal. Alternatively, component 2A may be made of any other material or combination of materials that in conjunction with coating 2B has posability. An exemplar linkage 2 comprised of component 2A and coating 2B may have a diameter D, although an exemplary linkage 2 without a coating 2B may have the same or similar diameter D.
D_Mand T_Cmay be such that linkage 2 may be (i) dimensioned so that it can be received within an opening 5 and/or an exit 6 of an exemplary block 10; (ii) dimensioned so that it can be received within fabric, flexible plastic, or elastomer tubing (all of which may be a cover or coating 2B); (iii) dimensioned so that D is within the range of diameters between those of opening 5 and those of exit 6 of an exemplary block 10; (iv) dimensioned to have a D of approximately 0.123 inches to approximately 0.193 inches; and (v) be dimensioned as approximately 5- to approximately 14-gauge wire. In a most exemplary embodiment, D is about 0.12574 inches in diameter and component 2A is made from a flexible aluminum armature wire. In another exemplary embodiment, D_Mmay be between about 0.0625 inches and about 0.12574 inches. Additionally and/or alternatively, T_Cmay be between about 0.0315 inches and about 0.0070 inches. Those skilled in the art may readily understand that the features of linkage 2 in FIGS. 16A-D are for purposes of illustration only, and these features may be changed, interchanged, isolated, combined, or otherwise varied with respect to any disclosed embodiments.
An exemplary coating 2B may be an elastomer selected from the group comprising poly-isoprenes (e.g., rubber, natural rubber), polyethylenes (e.g., Alathon, Alkathene, Fortiflex, Hi-fax, Petrothene, Rigidex, Rotothene, Zendel), polystyrenes (e.g., Carinex, Dylene, Hostyren, Lustrex, Styron, Vestyron), polyurethane, buna-N, butyl, SBR, neoprene (Chloroprene), silicone, polybutadiene, and other flexible elastomers known to those skilled in the art. An exemplary elastomer may be colored to match one or more exemplary bricks 10/30-70 to which an exemplary posable linkage 2 may couple and/or interconnect. Additionally, coating 2B may have structures formed on it to allow connection between the outer-most surface of linkage 2 and other Lego-like bricks. Those skilled in the art would understand the use of plasticizers to improve flexibility and ductility of an exemplary coating 2B.
In an exemplary embodiment, an exemplary linkage 2 may be particularly dimensioned to friction-fit within the circular opening 5 used on Erling Lego blocks, such as block 60 for example, and others with such opening (block 10/30/40/50/70), and still be maneuvered and posed in three-dimensional space while substantially maintaining their conformation, e.g., have posability. According to such an exemplary embodiment, an exemplary linkage 2 may have a D_Mof about 0.0625 inches and a T_Cof about 0.03125 inches. In another exemplary embodiment, an exemplary linkage 2 may have sufficient size to friction-fit within the cylindrical opening 5 used in Lego® Technic block systems, e.g., block 70, and/or Lego® Erling blocks, e.g., block 60, and still be maneuvered and posed in three-dimensional space while substantially maintaining their conformation, e.g., have posability. According to such an exemplary embodiment, an exemplary linkage 2 may have a D_Mof about 0.0125 inches and a T_Cof about 0.00074 inches. In yet another exemplary embodiment, as may be further discussed with respect to FIG. 16D, an exemplary linkage 2 may have a coating 2B with a T_Cthat is of such size and elasticity so as to deflect when entering an opening 5 and/or 6 of an exemplary building block, such as block 10/30-70, and yet exert a force against the inner surfaces 8 of the opening 5/6 of that block that is no greater than the modulus of resilience of the structure making up the opening 5 and/or 6 of the block 10/30-70.
In one exemplary embodiment as illustrated by FIG. 16A, a posable linkage 2 with a D of approximately 0.1257 inches may have a 907A or 907C aluminum armature wire component 2A, such as the type that is sold by The Compleat Sculptor, NY, N.Y., Sculpture House, Skillman, N.J., and such that is made and sold by Arcor Electronics, Niles, Ill. An exemplary component 2A may have a D_Mof approximately 0.06285 inch and which may be coated with an elastomer 2B substantially about its length having a T_Cof approximately 0.031925 inches. More particularly, such an elastomer 2B may be a type of rubber.
In a first embodiment, 2*T_C+D_Mmay be the diameter of an exemplary opening 5/6 in a Lego-like block. In a second embodiment, 2*T_C+D_Mis slightly greater than the diameter of an exemplary opening 5/6 in a Lego-like block. In a third embodiment, 2*T_C+D_Mis equal to the diameter of the circular opening 5 in an Erling Lego block 60. In a fifth embodiment, 2*T_C+D_Mis equal to or slightly greater than the diameter of the circular opening 5 in an Erling Lego block 60. Where 2*T_C+D_Mis greater than the diameter of the aperture into which linkage 2 head 1 or tail 0 is inserted, an exemplary linkage 2 with such T_Cand D_Mmay utilize its elastomeric qualities or take advantage of the modulus of resilience of the exemplary block opening 5/6. An elastomeric coating 2B may be utilized due to its ability to deform in response to contact forces and thereby allow a user to insert a linkage comprising a component 2A with such a coating 2B into a Lego-like block opening while maintaining friction-like contact, reduced wear on the block opening, non-contact with metal, and/or minimal manufacturing costs. Further and alternatively, an elastomeric coating 2B may allow linkage 2 to have a D greater than the diameter of block opening 5 and/or 6 because such a coating 2B can deform while being inserted into the same (see, for example FIG. 16D and related disclosures). Depending on its elasticity, coating 2B may advantageously be applied to component 2A so that the linkage 2 may have a diameter D greater than that of the opening 5/6 into which linkage 2 is to be placed, yet still effectively friction fit with one or more exemplary blocks 10/30-70 to form one or more robust joints 20.
According to an exemplary embodiment as illustrated in FIG. 16B, an exemplary linkage 2 may comprise a component 2A of length L_Mand a coating 2B of length L_C. In an exemplary embodiment, L_Cis about the same length as an exemplary metal component 2A. In another exemplary embodiment, L_Cis between about 85-95% of the length of metal component 2A so that the coating covers all but a length of the ends of the metal component 2A that are sufficient to couple the linkage 2 of this exemplary embodiment in an exemplary block 10/30-70, e.g., L_T. In yet another exemplary embodiment, L_Cis whatever length necessary to leave about 0.090-0.150 inches of the end of a metal component 2A exposed on either side or both sides of linkage 2, e.g., an L_T=0.090-0.150. In another exemplary embodiment, coating 2B may envelop metal component 2A on all sides, as may be shown in FIG. 16C by an exemplary face coating 2C. In another exemplary embodiment, where a Lego brick 10/50/60/70 is used for receiving an exemplary linkage 2 of length L_C, the length L_Cmay be no greater than about 110-115% the length of L_Mso that the linkage does not interfere with other structures trying to fit within Lego brick 10 (e.g., other Lego bricks 10, 50-70, other exemplary linkages 2). In an exemplary embodiment where L_Tis the length of component 2A on which contours 3 a-e, and 3 g may be found, such contours 3 a-d, and 3 g may be disposed such that enough contours 3 a-e, and 3 g can frictionally engage opening 5/6 of an exemplary block 10/30-70 or the exemplary opening 16 of an exemplary socket 15. L_Cmay be a function of L_M, T_C, D_M, D, L_T, and combinations thereof. In this context, “function of” refers to any known mathematical operation or series of operations involving one or more of L_M, T_C, D_M, D, L_T, and operations involving the same.
In an exemplary embodiment all lengths L_Mand L_Cmay be based on the number of studs and/or Lego Drawing Units (“LDU”) of exemplary Lego blocks 10, e.g., two stud lengths, three stud lengths, four stud lengths, etc., as would be understood by a person of ordinary skill in the art. In an exemplary embodiment, length L_Cand/or L_Mmay be between about 4 and about 8 LDU in length as measured from the forward-most end of the linkage 2. In this exemplary embodiment, length L_Cand/or L_Mmay be such as to enable linkage 2 to avoid interference between itself and other structures traveling through an exemplary block 10. In yet another exemplary embodiment, length L_Cand/or L_Mmay be between about 2 and about 16 LDUs in length as measured from the forward-most end of an exemplary linkage 2, e.g., section 2C/D or the head/tail 1/0 made up of only component 2A. In still other exemplary embodiments, length L_Cand/or L_Mmay have the same LDU lengths as the smallest and/or longest Lego blocks known to those skilled in the art. L_Tmay be a length of metal component 2A sufficient to allow for a UNF Fine Thread # 0, 7 threads, 0.010 inch chamfer and a 0.0125 inch thread relief zone between coating 2B and the most proximal thread 12.
In an alternative embodiment, as illustrated by FIG. 16B, an exemplary posable linkage 2 may comprise a component 2A of length L_Mwith contoured ends 3 a-d/g and/or thread ends 12 and terminus 11 opposite head/tail 1/0. In this illustrative embodiment, a coating 2B may substantially cover a metal component 2A over a distance L_Cand leave exposed a length L_Tfor contouring 3 or threading 12. In an exemplary embodiment where L_Mis a length of component 2A with threading, the types of thread ends 12 and lengths (L_M, L_C, and L_T) that may be used for an exemplary linkage 2 may be shown in Table 1 (those skilled in the art would understand that the value of L_Tand the threading type/number of threads may correspond to one or more of the length and/or threading of channel 16, 16 a-b and channel threads 18 of an exemplary brick or block 10/30-70 and/or the length and threading of channels and threads in socket 15/15 ₁, including the spacing and length of use of socket structures 15 a, 17, and/or 17 a):

TABLE 1

Exemplary Illustrative
Embodiments (FIGS. 3A, 3D,				Threading
6B, 7B, 7F, 11C, 12C,				Type/number
13A-C, 15, & 16B-C)	L_M	L_C	L_T	of threads

I	0.625	inches	0.400	inches	0.100	inches	UNF #
II	1.250	inches	1.000	inches	0.100	inches	UNF #
III	2.500	inches	2.200	inches	0.100	inches	UNF #

IV	1.000	inches	0.700	inches	0.150	inches	8	threads
V	4.000	inches	3.750	inches	0.120	inches	7	threads
VI	8.000	inches	6.000	inches	0.550	inches	12	threads
VII	1.250	inches	0.700	inches	0.250	inches	10	threads
VIII	0.500	inches	0.300	inches	0.100	inches	6	threads

IX	3.000	inches	2.500	inches	0.250	inches	UNF #0
X	⅔	inches	⅓	inches	⅙	inches	UNF #	0

In the illustrative exemplary embodiments of FIGS. 16B-C, an exemplary linkage 2 may have threaded sections 12 that are further from the axis of the linkage 2, e.g., they are located outside the diameter of component 2A, with or without coating 2B. While threaded sections 12 may be illustrated in FIG. 16B, contoured sections 3 a-e/g may also be used in place, or used as per the illustrative embodiment of FIG. 16C, such that one or more of their individual heights or the average height of all such contours, extend beyond the non-threaded/non-contoured diameter of component 2A, D_MnT. In an exemplary embodiment, a threaded section 12 may have a height H_Tthat makes the threaded section 12 have the same or slightly larger D compared to the central cross-section of linkage 2 (e.g., linkage 2 with and without coating 2B). In an exemplary embodiment, the height of threaded section 12, H_T, may be about 0.0625 inches from an axis running perpendicular to the cross-section of linkage 2. At this exemplary height, threaded section 12 may couple a plurality of threaded Lego blocks 10 together, such as those illustrated and described with respect to FIGS. 7A-F. Alternatively, threaded section 12 may couple a plurality of threaded non-Lego type blocks 10, e.g., K'nex, Construx, together.
In an exemplary embodiment, threaded sections 12 may result from thread rolling or other such cold rolling machining processes as described with respect to FIG. 18 and which may are known to those skilled in the art. In an exemplary embodiment, the ratio of (H_T+D_MnT) to D is between about 0.80 to about 1.64. In an alternative exemplary embodiment, the ratio of H_Tto D_MnTis between about 0.05 to about 0.20. Where an exemplary linkage 2 has a plurality of contours 3 a-e/g, D_MnTmay be calculated by taking the average cross-section as previously described, and H_Tmay be calculated by taking the average of the peaks and troughs of each of the plurality of contours 3 a-e/g as compared to the D_MnT, where all peaks and troughs above D_MnTto have positive values and all peaks and troughs below D_MnTto have negative values.
In the illustrative exemplary embodiment of FIG. 16C, an exemplary linkage 2 of diameter D may have a coating 2B over substantially its entire length L_Mso that L_Cmay represent the operative length of linkage 2. Those skilled in the art may appreciate that FIG. 16C may illustrate embodiments of an exemplary linkage 2 having a metal component 2A covered in a flexible tube 2B. Alternatively, FIG. 16C may illustrate various surface features of an exemplary linkage 2, but it should be understood any of the illustrated features may be found in isolation of other features or over different distances, depths, and have different shapes, angles, dimensions, configurations, and properties, including partial, intermittent, and complete covering arrangements. For example, an illustrative linkage 2 of FIG. 16C may comprise contours 3 a-e/g and threads 12 as disclosed for linkages 2 from FIGS. 3A-D, but it may comprise one or more such features in different forms. For example, an exemplary linkage 2 may have a coating 2B, wherein the coating 2B may have threads 12 at both head 1 and tail 0 of the linkage 2. Alternatively, coating 2B of an exemplary linkage 2 may have only contours 3 a-e/g and no threads along its length L_C. Any of the surface geometries illustrated by and/or described with respect to FIG. 16C may apply equally to exemplary linkage coatings, such as coating 2B, of any other figures, including, but not limited to, FIGS. 3A-D, 16A-B, 5, 11, and 15.
As further illustrated by FIG. 16C, an exemplary component 2A may have a major diameter D_Mand a minor diameter D_m. For an exemplary component 2A with a minor diameter D_m, D_mmay be dimensioned to engage one or more internal contours 3 f of coating/tube 2B. An exemplary contour 3 f may allow for better adherence of coating/tube 2B to component 2A, may allow for greater resistance to tearing, wearing, disengagement with, or over-stretching of coating/tube 2B, e.g., in response to flexing or movement of component 2A. In an exemplary embodiment, an exemplary coating/tube 2B may be dimensioned, including use of contours 3 f, so as to allow linkage 2 to satisfy Section 9.3.6 Flexure Test of the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing. An exemplary D_mmay also serve to participate in formation of contours on coating/tube 2B during a coating process as discussed with respect to FIG. 18. In this manner, a component 2A with a particular pattern of D_Mand D_mmay be contoured (e.g., contours 3 a-d/g, 12) so that when a coating 2B is applied, an internal contour 3 f may be formed and an external contour 3 a-e/g and/or 12 may be formed. As further illustrated in FIG. 16C, coating contours 3 e may be among any of the coatings 3 a-d/f/g/h described herein, including combinations and patterns of the same.
As further illustrated in FIG. 16C, an exemplary face coating 2C may be at the head 1 and/or tail 0 of an exemplary linkage 2. An exemplary face coating 2C may have the same or lesser friction than coating/tube 2B. An exemplary face coating 2C/2D may provide a soft zone or flexible buffer region for an exemplary metal component 2A to allow such a linkage 2 to satisfy any of the tests found in section 18 of the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing, in particular all subsections of section 9.2 and 18, in particular, section 9.2.4 Sharp Point Test, 9.2.5 Sharp Edge Test, and 9.3.6 Flexure Test. While a face coating 2C/2D may be used to satisfy the aforementioned tests, as disclosed herein, an entirely metal linkage 2 or a linkage 2 comprising flexible coatings substantially along its length but with exposed metal faces and/or ends may also be configured to satisfy the tests of the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing, including Sections 9.2.4, 9.2.5, 9.3.6, and 18. In an exemplary embodiment, face coating 2C/2D may have a maximum amount of material at a height of 0.5D and/or 0.5D_M. In another exemplary embodiment, face coating 2C/2D may have multiple peaks, valleys, and/or protrusions of various cross sections, e.g., circular, rectilinear. Furthermore, the illustrative embodiment of FIG. 16C may result from extrusion coating a length of component 2A and then molding its extremes to create a face coating 2C/D using a heated mold, lathes, presses, or other surface molding techniques known to those skilled in the art.
As further illustrated in FIG. 16C, one or more thicknesses of coating 2B may be found on an exemplary component 2A of an exemplary linkage 2. In one embodiment, coating 2B may have a thickness T_C1measured from an outside contour 3 a-e/g and/or thread 12 to an inside contour 3 f. In another embodiment, coating 2B may have a thickness T_C2measured from a non-contoured surface of the coating 2B to the most radially proximal surface of component 2A. In this embodiment, an area of surface of coating 2B may be considered “non-contoured” if surfaces within the square area maintain the same perpendicular distance from the axis of component 2A. In another embodiment, coating 2B may have a thickness T_C3measured from a contoured surface 3 e of coating 2B to the most-radially proximal surface of component 2A. In another embodiment, coating 2B may have a face coating 2C of thickness T_C4measured from the outer surface of face coating 2C to the closest surface of component 2A. In yet another embodiment, coating 2B may have a face coating 2D of thickness T_C5measured from the furthest end of linkage 2 to the furthest end of component 2A.
In an exemplary embodiment, T_C1, T_C2, and T_C3are substantially equal. In another exemplary embodiment, one or more of T_C1, T_C12, or T_C3is no greater than about 0.01 inches to about 0.05 inches, such as, for example, 0.031925 inches. In yet another exemplary embodiment, T_C2is always less than T_C1. Alternatively, in another exemplary embodiment, T_C3is substantially equal to T_C1. In yet another exemplary embodiment, T_C3may be any of the values for exemplary threads 12 in Table 1. In another embodiment, T_C4and T_C5are dimensioned to comply with the June 2010 United States Consumer Product Safety Commission Laboratory Test Manual for Toy Testing, including Sections 9.2.4 and 18.
In another exemplary embodiment, T_C4is substantially equal to T_C5. Alternatively, T_C4may be greater than, less than, a fraction of, or a multiple of T_C5. In an exemplary embodiment, T_C1, T_C12, T_C3, T_C4, T_C5, and combinations thereof may be dimensioned to allow exemplary linkage 2 to enter one or more openings 5/6 of an exemplary block 10/30-70 and engage the opening 5/6 sufficiently to be posed while also being situated therein. In another exemplary embodiment, L_Cdoes not necessarily equal L_M+T_C4. In such an exemplary embodiment, coating 2B may have a coating surface located at L_M−T_C4, in particular, when the ends of component 2A have their own contours 3 f at their axial extrema.
As may be shown in the illustrative embodiment of FIG. 16D, an exemplary joint 20 may be shown. As illustrated, a joint 20 can be shown in cross-section such that an exemplary linkage 2 may be cut to expose its component 2A and coating sides 2B and an exemplary block 10 may be cut to expose the cross-section of an opening 5. While opening 5 has been shown, it is understood as previously described that any other opening 5/6 or other aperture or cavity may be contemplated. In the illustrative embodiment of FIG. 16D, exemplary head/tail 1/0 of an exemplary linkage 2 has been coupled with block 10 so that an exemplary coating 2B of a flexible type, such as, for example, an elastomer material, deflects as it enters opening 5. While head/tail 1/0 may be shown with a convex surface for an exemplary linkage 2, head/tail 1/0 may alternatively be any of the aforementioned shapes and surfaces described, for example, concave, jagged, labyrinthine.
Accordingly, coating 2B has a first height X₁, which may be the radial height from the center of linkage 2, the thickness T_C, or other measurement with a defined reference point. As coupled via opening 5, an exemplary linkage 2 may have a junction contour 3 h formed in its coating 2B and which may be at a height X₂. X₂may be slightly less than the height X₁of coating 2B. The portion of linkage 2 that may be coupled within an exemplary block 10/30-70 may have a coating 2B that is at a height X₃, which is at least less than the height X₁, and may, in certain embodiments, be less than the height X₂. In an exemplary embodiment the ratio X₂/X₁may be between about 0.925 and about 0.999. In another exemplary embodiment the ratio X₃/X₁may be between about 0.8725 and about 0.99. In an exemplary embodiment, X₃/X₁may be between about 0.95 and about 0.90 for both a resilient and flexible coating 2B that may exert friction forces on the inside of opening 5 of an exemplary block 10/30-70.
According to the illustrative embodiment of FIG. 16D, the portion of an exemplary head/tail 1/0 of an exemplary linkage 2 that contacts the opening 5 of block 10/30-70 may be a length L_K. In an exemplary embodiment L_Kmay be less than the depth of opening 5 of block 10 measured from the outermost edge of opening 5 to cavity 8 of an exemplary block 10, e.g., ¼ of the depth, ½ of the depth, or ¾ of the depth. Alternatively, L_Kmay be such that a free length of an exemplary linkage 2 within an exemplary block 10, denoted L_F, does not interfere with other structures trying to fit within Lego brick 10 (e.g., other Lego bricks 10, other exemplary linkages 2). Further alternatively, L_Kmay be based on the number of studs and/or LDU of exemplary Lego blocks 10, e.g., two stud lengths, three stud lengths, four stud lengths, etc. In an exemplary embodiment, length L_Kmay be between about 1 and about 3 LDU in length as measured from the forward-most end of opening 5. In an exemplary embodiment, length L_Fmay be between about 1 and about 2 LDU in length as measured from the boundary of an exemplary cavity 9 and an exemplary opening 5 of an exemplary block 10/30-70. Alternatively, L_Fmay be measured from the surface within an exemplary block 10/30-70 that either (i) lies in a plane that is orthogonal to opening 5, or (ii) whose central axis is orthogonal to the central axis of opening 5.
With further reference to FIG. 16D, an exemplary linkage 2 may be coupled to an exemplary block 10/30-70 via opening 5 or any other disclosed aperture by compressing an exemplary elastomeric coating 2B from a height of X₁(outside of opening 5), to a height X₂(on the border outside or inside of opening 5), to a height of X₃(inside of opening 5). In alternative embodiments, coating 2B may regain some, all, or none of its original height X₁once inside cavity 8 of the aforementioned exemplary block, wherein that cavity height is X₄. An exemplary internal coating 2B height X₄may be the height at any point on coating 2B along L_F. In an exemplary embodiment, the ratio X₄/X₁may be between about 0.975 and about 0.999.
FIG. 16D may be used to illustrate one exemplary concept of the operation of an exemplary linkage 2 in terms of its activity at the block opening 5 of an exemplary block, as previously described. An elastomeric coating 2B may be joined to component 2A as per coating process 520 as described with respect to FIG. 17. An exemplary coating 2B may have a juncture 2J with component 2A that may contain one or more adhesives, welds, stitches, and/or impregnated material into component 2A, or combinations of the same. Alternatively, where coating 2B may be a tube, juncture 2J may be a substantially non-permanent junction between component 2A and coating 2B, e.g. it may rely on friction or other mechanical couplings that do not modify the material of the component 2A and/or the coating 2B.
As will be further discussed, an exemplary linkage 2 may be coated with coating 2B about substantially its entire length first, stripped at its ends to expose underlying metal component 2A second, and thread rolled and/or subject to any other known thread-forming and cold rolling technique known to those skilled in the art and shown and described with respect to FIG. 17, processes 520, 530, and 540 to form threads or contours on the exposed metal sections of component 2A on length L_T. However, in an alternative exemplary embodiment, the aforementioned steps may be done in reverse order depending on the instrumentation and capabilities to coat thread-rolled and/or cold-rolled linkage metal component 2A of an exemplary linkage 2 with coating 2B so as not to substantially interfere with the prior-formed threading 12 of linkage 2. In an exemplary embodiment, the threaded metal component 2A may be screwed into chucks (not shown) and then coated with coating 2B so that unscrewing the coated, thread-rolled component 2A will leave un-coated the threads 12 formed prior to chuck application. While the foregoing embodiment may rely on a chuck to prevent coating of exemplary linkage 2 threads 12, those skilled in the manufacturing art may recognize other techniques and arrangements to avoid coating the threads 12 of an exemplary linkage 2.
FIG. 17 is an illustrative embodiment of a process 500 of manufacturing an exemplary linkage 2 for use with an exemplary block 10/30-70, and/or linkage-block joint 20 as illustrated and/or described by way of disclosures herein and all interrelated disclosures. During an exemplary drawing step 510, an amount of material, such as a metal, may be extruded, cut, folded, 3D-printed, sintered, machined, or otherwise formed. Those skilled in the material fabrication arts may understand the various processes involved in the formation of metal wires, such as, for example aluminum armature wire, copper wires, brass wire, and alloys and galvanized variants of the same. In another aspect of this exemplary embodiment, an exemplary drawing step 510 may include unwinding a roll or packing of previously-formed material, such as, for example, a wound length of metal wire. An exemplary drawing step 510 may include extruders, cams, pulleys, drive wheels, calendars, rollers, and other equivalent structures used by those skilled in the manufacturing art to move material from one location to another in a controllable fashion. While not as efficient, manual drawing of material for an exemplary process 500 may also be contemplated. The material drawn in drawing step 510 may be the entire linkage 2 or a component of linkage 2 (e.g., component 2A, component 2B, or component 2A and 2B alone or in combination).
Where a coating 2B may be applied to a component 2A via decision step 515, an exemplary coating step 520 may involve placing a coating 2B on a portion of or substantially about the entirety of a length of the drawn material, including placing an intermittent or discontinuous pattern about the material length. An exemplary coating step 520 may rely on spraying the material about the component 2A, co-extruding the coating about the length of material as it is passed through the same extruder, dipping the material in a bath or mold of material and then cooled, and/or slipping the material into a coating sleeve, jacket, tube, or other integrated construct that can envelop the material. In an exemplary embodiment, the coating 2B is a flexible material, such as fabric, rubber, and/or elastomer. In a further exemplary embodiment, the coating 2B is silicone, rubber, or combinations/isomers thereof. In a yet further exemplary embodiment, the coating 2B is co-extruded onto the length of wire (L_M) substantially about its entire length, such as, for example, L_C. An exemplary coating step 520 may result in one or more of the various linkage 2 embodiments illustrated and disclosed with respect to FIGS. 1-16, and further in particular, FIGS. 16A-D and 18A-D.
As described, an exemplary process 500 may involve certain decision steps, such as those exemplified in decision steps 515, 525, and 527. Decision steps may be undertaken manually or through use of automated methods, such as data acquisition (DAQ) equipment arranged about the process components that undertake the steps of process 500. For example, an exemplary coating decision 515 may involve a pre-programmed computer algorithm that may take inputs from sensors installed in an exemplary process 500 assembly line, and decide whether a coating 2B need be applied to an incoming component. According to an exemplary embodiment, a laser measurement tool known to those skilled in the art may be used to measure the distance from a fixed distance to the surface of a constituent of an exemplary linkage 2. Thus, if the constituent, such as component 2A, is at a larger distance than a component 2A that is coated with 2B, an exemplary decision step 515 may involve sending the distance measured to an algorithm that determines whether to direct the component 2A to be coated, e.g., use of “if-than-else” statements, lookup functions such as those used in Excel Visual Basic for Applications (“VBA”) which includes, but is not limited to the following exemplary functions and/or algorithms: hlookup, vlookup, getpivotdata, lookup, and match. In a more particular embodiment, an exemplary algorithm may be written in any language for operation by a computer, such as those known to persons skilled in the programming arts (e.g., C+, C++, Java, Sequel, Perl, HTML, Assembly, Visual Basic, Q Basic, and others identified via the following website as of the date of these disclosures—https://en.wikipedia.org/wiki/List_of_programming_languages). Alternatively, those skilled in the art can control performance of an exemplary process 500 as illustratively shown in FIG. 18 via Simulink, Matlab, or other known control systems.
In an exemplary algorithmic form of decision step 525, the measurement of an analog or digital device may be retrieved, e.g, the signal representative of the horizontal measurement between a laser and a component 2A (referred to herein as step 525(i)), compared to a known quantity, e.g., the horizontal measure of the laser origin to the linkage 2 component 2A plus the thickness of an exemplary coating 2B (which may be adjusted by a user) (referred to herein as step 525(ii)), and take a specific action in the process 500 based on the comparison (referred to herein as step 525(iii)).
For example, an exemplary decision step 525(ii) may determine whether the measurement data received is less than the distance from the measurement device to linkage 2 component 2A, and if so, instruct the processor of the computer to send a signal (analog or digital) to the controllers to progress the linkage 2 to the next step of an exemplary process 500. Alternatively in the aforementioned exemplary embodiment, decision step 525(ii) may yield a value greater than the horizontal measurement plus the thickness 2B, in which case the activity portion of the algorithmic decision step 525, namely, 525(iii), may involve the delivery of a signal controlling coating, rotors, and actuators to move linkage 2 through a coating device, such as a polymer/elastomer extruder, in order to begin the exemplary coating 520 step of an exemplary process 500. In an even more particular embodiment, when a laser sensor is 0.5 inches away from an exemplary component 2A of circular cross section and measures a distance equal to or greater than about 0.53175 inches, then the sensor signals to the remainder of the systems in process 500 to put the coating 2B on the component 2A.
In an exemplary process 500, decision step 525 may include analyzing whether the coating 2B applied to an exemplary component 2A in step 520 results in an L_Cthat is greater than or equal to L_M. An exemplary decision step 525 may be determined using laser scanners, optical sensors (e.g., optical LEDs to determine presence of coating via light reflected off the coating), point and roller probes to determine presence of plastic or elastomer up and down the length of linkage 2, or manual inspection.
In an exemplary process 500, decision step 527 may include a pre-set determination of a contoured component 2A in addition to or exclusive of a contoured coating 2B. Thus, an exemplary decision step 527 may be algorithmic to the extent a contoured component 2A may be required in certain amounts based on the number of contoured coatings 2B, based on a pattern of contoured component 2A manufacture, or based on a demanded amount delivered to the algorithm via online or other means as a number of units. An exemplary algorithmic decision step 527 may decide whether to contour a component 2A of linkage 2 based on a voltage or other digital input (“1” to signal contour component 2A, “0” to signal do not contour component 2A). As a result, in an exemplary process 500 in which component 2A of linkage 2 is to be contoured, the coating 2B may be removed from linkage 2 during an exemplary stripping process 540. If contouring of component 2A is not required, the linkage 2 may be scheduled for cutting as per an exemplary cutting process 530.
All decision steps disclosed for an exemplary process 500 may be represented in algorithmic form as would be understood by a person of ordinary skill in the programming and manufacturing arts. Alternatively, the algorithms for an exemplary decision step 515/525/527 may be a control feed-back loop that uses the output of an exemplary process 500 at any stage of the process to determine what decision is to be made in the step. For example, an input into any one of the algorithmic versions of decision steps 515/525/527 may be the amount of contoured linkages 2 with coatings 2B, which triggers the decision steps individually or together to balance that amount with an equal number of non-contoured linkages 2, with and without coating 2B.
An exemplary cutting step 530 may involve manual, semi-automatic, or automated cutting processes to shorten a length of material, whether coated or not coated as per coating step 520. An exemplary manual cutting step 530 may include use of lathes, saws, lasers, blades, or other mechanisms known to those skilled in the manufacturing arts sufficient to separate lengths of material from other lengths of material. In an exemplary semi-automatic cutting process 530, linkage 2, whether coated or not coated as per coating step 520, may be manually held while acted upon by an automatic cutting machine of the type known to those skilled in the art, such as, for example, machines and mechanisms manufactured by Schleuniger Inc. of Thun, Switzerland, such as, for example, the EcoStrip series of machinery, or the EcoStrip 9320 automatic cut and strip machine. Other like machinery and mechanisms suitable for use in an exemplary cutting process 530 are also within the knowledge of those skilled in the manufacturing arts.
Alternatively, linkage 2, whether coated or not, may be controllably cut about its length via cams, rollers, conveyor belts, and other automated apparatus known to those in the manufacturing arts. An exemplary cutting process 530 may utilize the automated cutting system provided by machines and mechanisms manufactured by Schleuniger Inc. of Thun, Switzerland, such as, for example, the EcoStrip series of machinery, e.g., the EcoStrip 9320 automatic cut and strip machine.
An exemplary stripping step 540 may involve manual, semi-automatic, or automated stripping process. In one embodiment, an exemplary stripping step 540 may be used to shorten the amount of coating 2B, e.g., L_Cor T_C, on an exemplary component 2A of linkage 2. Alternatively, an exemplary stripping step 540 may be used to remove a portion of an end of linkage 2 to expose component 2A, such as may be seen in one variant of the illustrative embodiment of FIG. 3A where a coating 2B may be shown as the threads 12 and the exposed end of component 2A as terminus 11. In an exemplary embodiment, an automatic cutting machine of the type known to those skilled in the art, such as, for example, machines and mechanisms manufactured by Schleuniger Inc. of Thun, Switzerland, such as, for example, the EcoStrip series of machinery, e.g., the EcoStrip 9320 automatic cut and strip machine. In another exemplary embodiment, an exemplary cutting process 530 and an exemplary stripping process 540 may take place before or after the other, or directly after one another, as may be the case if using an EcoStrip series machine from Schleuniger Inc., as previously stated. Other like machinery and mechanisms suitable for the aforementioned stripping process 540 are also within the knowledge of those skilled in the manufacturing arts.
An exemplary channeling process 550 may be used to redirect cut, stripped, or otherwise processed product to either a contouring process, a collecting process, and/or a packaging process, such as, for example, the exemplary contouring process (560), collecting process (570), or packaging process (590) illustrated and described herein. An exemplary channeling process 550 may take advantage of any form of communication mechanism for physical products known to those in the industrial arts, for example, chutes, funnels, conveyors, cams, rollers, pulleys, lifts, robotic arms, magnets, pipes, tubes, vacuum/suction mechanisms, or equivalent means of moving product in an assembly line or production facility.
An exemplary channeling process 560 may be controlled by way of motion detectors, e.g., laser, pressure, vibratory, or other contact and/or non-contact sensors, or by use of mechanical components whose revolution may either permit open and closed access to travel (e.g., gears, cams, structures with intermittent openings in a path of rotation), or other mechanical passage controls (e.g., spring-loaded doors, walls, or panels that return to closed or open state after passage of a product, sifters).
In any of the aforementioned exemplary embodiments, an exemplary channeling process 550 may be controlled via feedback loops and other digital or analytical tools to monitor product output and/or extent of production, e.g., a computer, mobile device, video camera, analog recorder, or mobile application running on one or more of a computer or mobile device, such as a smartphone. Indicia of product production may be based on product passage over sensors, passage controllers, or by scanners electronically trained to detect the final products by material composition, color, length, or other mechanical, chemical, electrical, and/or other material characteristics.
For example, an exemplary channeling process 550 may incorporate a motion sensor known to those skilled in the art to detect when a product passes along its length and from that data provide the digital or analytical tool(s) one or more of: product speed of passage and number of completed product, for example. In one aspect of the foregoing example, product speed may be sent to a mobile device via text message or other such communication to alert an operator to progress of a job. In another aspect of the foregoing example, product number can be recorded for calculating job efficiency, cost, material, and production modifications. Those skilled in the industrial arts may be aware of many metrics, formulae, and equations by which to derive indicia of production efficiency, progress, quality control, output, resource usage, and/or forecasting.
In another example, an exemplary channeling process 550 may incorporate an assembly of magnet and pressure and/or motion sensor known to those skilled in the art, which may be used to attract a product with a posable metal linkage 2 so that it contacts the pressure or motion sensor. In an aspect of this exemplary channeling process 550, the product can be identified as having a sufficient degree of coating T_Cfor an exemplary posable metal linkage 2 so as to still be attracted by the magnet. In one additional aspect, the speed and pressure of the product may serve as factors to identify whether the product has been adequately coated with material 2B, is not overweight, or is sufficiently robust for end use.
An exemplary contouring process 560 may involve a die, tap, lathe, mold, threaded die, laser, pressured water jet, heat, steam, or other work or machining station known to those skilled in the art on which a linkage 2 may be given contours 3/3 a-h/11/12 on or in its surface(s). A linkage 2 may bypass any of the prior processes 510-550 and go directly to contouring process 560, depending on needs. For example, a 3D printing enabled process 500 may not require any material be coated (process 520) or cut (process 530), but may be formed in contouring process 560 which in this exemplary embodiment is exemplified by a 3D printing system, such as those described herein.
In an exemplary embodiment where a product goes through either one or more of processes 510-550, an exemplary contouring process 560 comprises receiving the linkage 2 and subjecting it to roll threading or other form of cold rolling process(es) known to those skilled in the manufacturing arts. According to this exemplary embodiment, a product, such as the exemplary product embodiments illustratively disclosed and described with respect to FIGS. 16A-D, may be formed by such a thread rolling process 560. Equivalents of the illustrative embodiments of FIGS. 16A-D may also be formed by an exemplary thread rolling process 560. In another aspect of this exemplary embodiment, an exemplary thread rolling process 560 may be configured to provide threads 12 on a linkage 2 within and about the ranges and/or equivalent ranges described and disclosed with respect to Table 1.
In an exemplary contouring process 560, a product may be acted upon by other types of grinding, cutting, sintering, welding, cold forming, and/or machining known to those skilled in the art to create contours 3/3 a-h/11/12 as may be illustratively shown by FIGS. 3A-D, 4A-D, 4G, 5, 6B, 7B, 7F, 9A-B, 10B-C, 11B-C, 12C, 13A-C, 14D, 15, 16A-D, their related and interrelated disclosures, and any and all permutations, equivalents, and combinations thereof. For example, a die may be used to cold roll one or more of the contours 3/3 a-h/11/12 detailed in the aforementioned figures and related and interrelated disclosures. In another example, a sintering, lathe, laser cutter, CNC, or other material removal manufacturing process known to those skilled in the manufacturing arts may be used to create one or more of the contours 3/3 a-h/11/12 detailed in the aforementioned figures and related and interrelated disclosures. In one embodiment, FIG. 3D may illustrate an exemplary contoured linkage 2 made of one material or an exemplary linkage 2 having an intermittent coating 2B (denoted as 3 a) and one or more exposed portions of component 2A (denoted as 3). In another embodiment, FIG. 3A may illustrate an exemplary contoured linkage 2 made of one material or an exemplary linkage 2 having an intermittent coating 2B (denoted as 12) and one or more exposed portions of component 2A (e.g., terminus 11).
An exemplary collecting process 570 may involve any automated, manual, or combinations thereof whereby posable metal linkages 2 may be grouped, coupled, attached to, and/or otherwise oriented with one or more types of blocks disclosed herein, such, as for example blocks 10/30-70, exemplary blocks 10 of FIGS. 7A-E and 15, exemplary blocks 50 of FIGS. 7F and 15, exemplary block 60 of FIG. 12A, exemplary block 70 of FIG. 14C and/or blocks 30/40/50/60/70 manufactured by one or more of the processes herein described. An exemplary hybrid brick 50 may be the brick provided for an exemplary collecting process 570. An exemplary collecting process 570 may include funneling linkages 2 to repositories (e.g., buckets, bins, wells, and/or enclosures) that are also the repositories of a particular brick 10/30-70 from a similar funneling step. It may be possible to include an aspect of, part of, or a different aspect or part of the channeling process 550 described as part of the collecting process. Following collection in step 570, an exemplary packaging process 580 may be undertaken.
In an exemplary embodiment of the packaging process 580 of the exemplary process 500 illustratively set forth by FIG. 17, a manual or automatic packaging scheme may be utilized to place linkages 2, one or more types of brick 10/30-70, or combinations thereof into preformed boxes, bags, sealable bags, plastic and cardboard combinations, blisters, or other types of containers. Alternatively, an exemplary packaging process 580 may include combining an exemplary linkage 2 with one or more of the blocks collected previously as they would be assembled for use, e.g., placing a head 1 or tail 0 of a linkage 2 within an opening 5 of an exemplary block 10/30-70 to form a joint 20. In other words, an exemplary packaging process 580 may involve packaging an exemplary joint 20 for end use by the consumer to reduce the number of loose parts in the packaging, e.g., box or bag.
Furthermore, an exemplary packaging process 580 may also involve providing instructions to the end user or customer for use of linkage 2 or joint 20 with one or more bricks 10/30-70 or other Lego-like or non-Lego-like blocks incorporating such bricks or others. Such instruction provision may be via printed matter, such as instruction manuals, or through non-print media, e.g., audio or digital means, such as television, radio, text messages, voicemail, email, websites, online video, downloads (e.g., PDF, word documents, .txt files, mp3/mpeg files, power point files), social media, or other digital distribution networks and platforms known to those skilled in the marketing arts.
Another exemplary embodiment of posability may be seen with respect to FIGS. 18A-D. In the illustrative embodiment of FIG. 18A, an exemplary linkage 2 having a component 2A, which may be made out of a flexible metal, and a coating 2B, such as, for example, an elastomer or flexible plastic coating, may be coupled to an exemplary block or blocks 10/30-70 via an opening 5. Block or blocks 10/30-70 may be further coupled, either removably or integrally with block or blocks 100/200, which may be the same as blocks 10/30-70, a block described herein, or any conventional block in the prior art.
At the juncture between linkage 2 and opening 5, an exemplary metal component 2A of an exemplary linkage 2 may be found along a distance L_Kcircumscribed by opening 5 and a distance L_Fbeyond the walls of opening 5 and/or found in an exemplary cavity 9 of an exemplary block or blocks 10/30-70. As previously described, component 2A, which may be made of a flexible metal, may be located only along length L_Kwhile a coating thickness 2C may be found along a length L_F. Alternatively, component 2A may be located along L_Kand L_F. The ratio R of L_Fto L_Kmay be less than about 1.0, and in an alternative embodiment is no more than about 0.75. Depending on the size and configuration of opening 5 and block or blocks 10/30-70, ratio R may be any value that provides the benefits and advantages described herein. In another embodiment, L_Fmay be a length that is about equal to the thickness T_C4of linkage section 2C. In another embodiment, L_Fmay be a length that is about equal to the thickness T_C5of linkage section 2D. The person of ordinary skill in the art, by reviewing the interrelated embodiments of FIGS. 16A-D and 18A-D, will understand numerous interrelationships between L_C, L_M, L_F, L_K, T_C4, and/or T_C5that may be understood from the disclosures herein. In an exemplary embodiment, the person skilled in the art would understand the benefits of maintaining some length of component 2A within opening 5 of block or blocks 10/30-70 to increase friction and/or contact forces between coating 2B and the surface(s) of opening 5 of block or blocks 10/30-70.
With further reference to the illustrative embodiments of FIGS. 18A-D, an exemplary linkage 2 may be coupled to exemplary block(s) or brick(s) 10/30-70, such as, for example Lego® blocks, Lego-like blocks, hybrid blocks, and/or 3D printed blocks, which may themselves be connected to or be integral with blocks/bricks 100/200, such as Lego® blocks and non-Lego® blocks known to those skilled in the art. An exemplary linkage 2 may enter opening 5 of block(s) and/or brick(s) 10/30-70 along the x-axis. The plane tangent to the surface of block(s) and/or brick(s) 10/30-70 that intersects an exemplary linkage 2 may be perpendicular to the central-most axis of component 2A. At this juncture, the x-, y-, and z-axes for the intersection of the central-most axis of linkage 2 with block(s) and/or brick(s) 10/30-70, which together form joint 20, may be said to have their origins located there. However, persons of skill in the art may determine other locations along an exemplary linkage 2 and/or components 2A and 2B, or exemplary block(s) and/or brick(s) 10/30-70 that may serve as origins for the x-, y-, and z-axes, see, e.g., FIG. 2 and FIG. 15.
Referring to the illustrative embodiment of FIG. 18A, the component 2A of an exemplary linkage 2 may extend from opening 5 substantially along the x-axis while coating 2B may or may not extend from opening 5 substantially along the x-axis due to different contours 3/3 a-h in coating 2B, intermittent application of coating 2B on component 2A, and/or other configurations of coating 2B. However, in another exemplary embodiment, coating 2B may extend substantially along the same axes as component 2A, although it may not completely cover component 2A of an exemplary linkage 2. Furthermore, while coating 2B may extend along substantially the same axes as component 2A (e.g., the x-axis), an exemplary coating 2B may or may not extend from the same points as component 2A (e.g., only component 2A may be found along length L_F, while component 2B only begins to exist along length L_K, as may be the case for an exemplary linkage illustratively disclosed in FIG. 16B).
Referring to the illustrative embodiment of FIG. 18B, an exemplary linkage 2 may extend along the x-axis from opening 5 and then may be bent along the z-axis so that its cross-section is visible. While a portion of an exemplary linkage 2 may be posed in this manner, FIG. 18B may show an entire exemplary linkage 2, which has its head 1 covered by end coating 2C within block(s) or brick(s) 10/30-70 and its tail portion uncoated so as to leave component 2A exposed.
In use, an exemplary linkage 2 may be bent upon application of a user force, e.g., a positioning force that results from a user moving either the linkage 2 and/or a brick or block 10/30-70/100/200 coupled to the linkage 2, and is not one that results exclusively from gravity acting on the linkage 2 and/or the brick or block 10/30-70/100/200 coupled thereto). Such a positioning force may cause an exemplary linkage 2 to have a pose or conformation p. In an exemplary embodiment, p may comprise an “elbow” bend (which may be at a substantially right angle) or other arc-like bend. In an exemplary joint 20, there is minimal to no curvature ρ along length L_K, although at least some curvature ρ may be present along an exemplary linkage 2 (with or without coating 2B) at the outside facing end of opening 5 and/or at position X₂. An exemplary curvature ρ may be one or more curved portions of an exemplary linkage 2, and not necessarily just the portion of exemplary linkage 2 at opening 5.
Referring to the illustrative embodiment of FIG. 18C, an exemplary linkage 2 may extend from exemplary block(s) or brick(s) 10/30-70 along the x-axis and then be bent by a user in the y- and/or z-directions so as to have a pose or conformation p. As also illustratively shown, a portion of component 2A and the component 2's thickness T_C4of end covering 2C may together cover a distance of length L_F. The distance L_Killustrated may only relate to a portion of linkage 2 whose head 1 may be too long to fit within opening 5 of the particular block(s) or bricks(s). However, an exemplary linkage 2 may be configured so that the friction forces from opening 5 resulting from compression of a flexible covering 2B against a metal component 2A each serves to securely anchor exemplary linkage 2 within opening 5.
As illustrated in FIG. 18C, an exemplary linkage 2 may be bent by a user force into one or more conformations in positive and negative x-, y- and/or z-axis directions, as has been previously described. In any one of the exemplary conformations, including those illustratively disclosed with respect to FIGS. 18C-D, an exemplary linkage 2 may substantially maintain its pose ρ over a period of time. In an exemplary embodiment, ρ may have an origin at opening 5 (as shown from the origin of the x-, y-, and z-axes) and may triangulate with the endpoint of component 2A of an exemplary linkage 2 that is part of length L_Kinside brick/block 10/30-70 (point Q), the outer-most edge of opening 5 that is parallel to the y/z axes (point R), and all points along the length of ρ (shown in dashed and dotted line in FIGS. 18C-D) (point(s) S).
In an exemplary embodiment of posability, a posability triangle (“T”) may have angles α, β, and γ between lengths QS and RS, RS and RQ, and RQ and QS, respectively. In an exemplary embodiment α is always an acute angle between QS and RS, while β and γ may be any angle between RS and RQ and RQ and QS, respectively. In another exemplary embodiment, only when portions of an exemplary linkage 2 in ρ overlap themselves may β and γ be substantially 90 degrees. For certain lengths of exemplary linkage 2, only β may be substantially 90 degrees for one triangle T among all triangles T for a given ρ. For certain lengths of exemplary linkage 2, β and γ may be substantially 90 degrees for a plurality of triangles T among all triangles T for a given ρ.
In another exemplary embodiment, triangle T may have coordinates on the x-, y-, and z-axes. In another exemplary embodiment, triangle T may have coordinates on the x-, and only one of the y-, and z-axes. In another exemplary embodiment, QR may be the x-axis length of triangle T or T_X, which may be substantially equal to the length of component 2A along length L_K. In yet another exemplary embodiment, QR and/or T_Xlies substantially on the central axis of component 2A. In yet another exemplary embodiment, QR and/or T_Xlies substantially on the central axis of an exemplary linkage 2.
An exemplary posability of an exemplary linkage 2 may be contingent on the section modulus of plasticity and/or the area moment of inertia. In an exemplary embodiment, an exemplary linkage 2 may be configured so that its section modulus of plasticity (Z) may be defined by Equation 1:
$\begin{matrix} Z_{p} = \frac{{(D_{M - AVG} + 2 T_{C - AVG})}^{3}}{6} & Equation 1 \end{matrix}$
Where D_M-AVGmay be the average of all D_mand D_Mfor component 2A about L_Mplus L_T(to the extent component 2A has such contoured ends) and T_C-AVGmay be the average of all T_C1, T_C2, T_C3, T_C4, and T_C5for covering 2B about L_C. In one embodiment, a posable linkage 2 with component 2A and 2B may have a Z_pless than about 1.4000. In another embodiment, posable linkage 2 may have a Z_pless than about 0.58333.
In another exemplary embodiment of posability, an exemplary linkage 2 may be configured so that the area moment of inertia (“I”) for component 2A is less than that for covering 2B. Equations 2 and 3 provide an exemplary calculation for I for a wire-like component 2A (I_M) and a tubular covering 2B (I_C), respectively:
$\begin{matrix} I_{M} = \frac{{π (D_{M - AVG})}^{4}}{64} & Equation 2 \\ I_{C} = \frac{{π (D_{M - AVG} + 2 T_{C - AVG})}^{4} - {(D_{M - AVG})}^{4}}{64} & Equation 3 \end{matrix}$
In one embodiment, the smaller the area moment of inertia for an exemplary linkage 2, the greater the posability of the exemplary linkage 2. In an exemplary embodiment of posability, I_M<I_C. In an alternative embodiment of posability, I_Mmay be less than about 4.9×10⁻⁶in⁴and, in another alternative embodiment, I_Mmay be less than or equal to about 7.4×10⁻⁷in⁴. In accordance with these and other exemplary embodiments, I_Cfor an exemplary linkage 2 may be less than about 2.821×10⁻⁵in⁴. In an exemplary embodiment, the ratio of I_C/I_Mfor an exemplary posable linkage 2 may be greater than about 1 but less than about 50.
As a result of being inserted into an exemplary block 10/30-70 via opening 5, an exemplary linkage 2 may have a coating 2B that may exert the following restoring force (F_R) against opening 5 of one or more of the exemplary blocks and/or their hybrids described by, for example, Equation 4:
F _R =AE[(X ₂ −X ₁)/X ₁] Equation 4
Where A is the area of an exemplary coating 2B within length L_K. An exemplary A is equal to the product of the coating 2B thickness T_C, length L_K, and the product of the number pi (π) and linkage 2 diameter D. Alternatively, A may be equal to the product of
$\sum_{0}^{L_{K}} D - D_{M},$
length L_K, and πD. Further alternatively, F_Rand A may be the derivative of the force and/or area over length L_K. In a further alternative embodiment, A may be derived from any other formulae known to those skilled in the art for determining the area of coating 2B within length L_K. E is the modulus of elasticity of an exemplary coating 2B. The restoring force F_Rmay represent the force exerted by the compressed portions of coating 2B on the inside surface of an exemplary opening 5.
As a result of being inserted into an exemplary block 10/30-70 via opening 5, the exemplary length L_Kof an exemplary linkage 2 head/tail 1/0 may be held therein at least by a friction force F_Fexerted against the coating 2B according to, for example, Equation 5:
F _F=(F _R)(μ) Equation 5
Where F_Ris the restoration force for a deflected coating 2B and μ is the coefficient of friction for the opening 5 of an exemplary block 10/30-70. Thus, the dimensioning of an exemplary coating 2B vis-à-vis opening 5 may allow for greater frictional forces to retain an exemplary linkage 2 within an exemplary block 10/30-70. The friction forces F_Fmay be increased by the rigid attachment of coating 2B to an exemplary metal component 2A. In embodiments where blocks 10/30-70 are made of plastic, such as ABS or PLA plastic, an exemplary linkage 2 with a metal wire component 2A having a coating 2B adhered thereto may take greater advantage of the restoring forces F_Rgenerated as a result of coating 2B deflecting in response to insertion within such blocks 10/30-70. Application of Equation 2 may be made to determine the friction force of coating 2B (F_Fc) generated by the resistance forces of the opening 5 of the exemplary block 10/30-70 on coating 2B, where μ is that for the material of coating 2B. Use of an exemplary coating 2B in conjunction with component 2A may make for a more robust retention of an exemplary linkage 2 within the opening 5 of an exemplary block 10/30-70 and blocks incorporating the same.
In a further exemplary embodiment, as illustratively shown in FIGS. 19A-D, an exemplary linkage 2 of the type disclosed may be an integrated linkage 2E that may be integrally formed with a Lego-like block or brick 80 and/or be a welded linkage 2F that may be mechanically/chemically attached to a block/brick 90. Block/brick 80/90 may be a form of any block or brick 10/30-70, coupled or integrally formed with one of blocks 100/200, and/or may be a form of any other block or brick disclosed or known to those skilled in the art. For example, block 80 may be made out of a plastic or other material that can be integrated with the material comprising linkage 2E. In an exemplary embodiment, block 80 may be made of ABS plastic while linkage 2E may be made of a flexible metallic component 2A covered by a rubber coating 2B that is integrally molded to block 80. In an exemplary embodiment, the material comprising linkage 2E may be formed first and then integrated with the mold or fabrication tooling while making block 80 so that linkage 2E can be embedded within block 80 as it is formed and/or be “captured” by the material making up block 80 so as to form one component. An exemplary linkage 2E may be pre-treated to couple to a block 80 by increasing the surface area on the integration end of the linkage 2E, e.g., increasing grooves, gnarling, contouring, cold rolling, and other surface area increases known to those skilled in the art. An exemplary integration end of linkage 2E may be one or more of the head 1 or tail 0 sections of disclosed linkages 2.
In an alternative embodiment, FIGS. 19A and 19C illustrate an exemplary weld linkage 2F that may be adhered to or otherwise held by Lego-like block or brick 90 by way of glues, pressure welding, vibration welding, sintering, soldering, or plastic welding. The adhesion location for linkage 2F to Lego-like brick 90 may be at joinder section 92, which may be intermittent or substantially continuous along the length of linkage 2F bounded by Lego-like brick 90. In exemplary embodiments, linkages 2E and 2F, Lego- like blocks 80 and 90, component 2A, and coating 2B may be interchanged with, interrelated to, combined with, used as an alternative to, and/or modified by any of the disclosures of toy linkages and related systems herein.
An exemplary integrated linkage 2E may be embedded in block 80 as shown in FIG. 19B. As described with respect to FIGS. 16A-D, an exemplary integrated linkage 2E may have an overall diameter D that may be substantially the same as or less than the thickness of block 80, T_BR. Alternatively, an exemplary linkage 2E may have a component 2A of diameter D_Mthat is integrated with block 80. According to this exemplary embodiment, component 2A may have one section that may be integrated with block 80 and a remainder section that is not integrated with block 80, the “free” section, that may be component 2A in isolation, component 2A with covering 2B, and any form of other linkage 2 forms, components, coverings, and interrelationships disclosed. For example, an exemplary linkage 2E may be integrated with block 80 over a length equivalent to length (i) L_K, (ii) L_K+L_F, and/or (iii) L_T. Alternatively, an exemplary linkage 2E may have a threads 12 or contours 3 a-h at its head 1 to allow for better integration with block 80. In another embodiment, block 80 may be a more elaborate form of face covering 2C/D applied to a coated linkage 2.
An exemplary welded linkage 2F may be coupled to block 90 as shown in FIG. 19C. As described with respect to FIG. 16A-D, an exemplary welded linkage 2E may have an overall diameter D that may be substantially the same as, greater than, or less than the thickness of block 90, T_BR. In an exemplary embodiment, block 90 may have a repository Φ in its surface for a welded linkage 2F such that a portion of linkage 2F diameter D intersects block 90 thickness T_BR. In another exemplary embodiment, block 90 joinder sections 92 may be formed so that the diameter D of linkage 2F may be interconnected with a surface Γ or in the thickness T_BRof block 90. An exemplary diameter D of linkage 2F or surface Γ of block 90 may be treated to increase its surface area to permit an exemplary joinder 92 between both. While joinder 92 may be shown filling in the entire area between diameter D and block 90 surface Γ, this may not necessarily be the case, and air gaps, channels, and cavities may be present without affecting the goal. As previously described, joinder 92 may be comprised of a bonding agent or glue, a melted plastic or epoxy, a solder, a stitch, a staple, a vibration weld, pressure weld, sintered edge, and/or other weld form known to those skilled in the art. In an exemplary embodiment where linkage 2F may be a coated linkage having a cover 2B of thickness T_C, the thickness T_Cmay be smaller at joinder sections 92 than elsewhere on linkage 2F to account for chemical/mechanical augmentations to allow coupling of linkage 2F to brick 90. Alternatively, an uncoated section of linkage 2 F having threads 12 and/or contours 3 a-h may also interact with joinder section 92 and may be the sole section on linkage 2F to couple with block 90. In accordance with this embodiment, the smaller diameter D_mmay be used to weld linkage 2F to block 90 while the larger diameter D may exist outside of the junction zone formed by joinder 92 and surface Γ. An exemplary surface Γ may be equal to approximately 0.465*D or approximately 1.500*T_C.
In the exemplary embodiment of FIG. 19D, an exemplary integrated Lego-like block 80/90 may also have a user force applied to its integrated linkage 2E or weld linkage 2F so as to cause either linkage to maintain a pose ρ in the x-, y-, and z-plane. The origin of the pose ρ may be found at the junction of the axis of an exemplary linkage 2E/2F and the orthogonal surface of Lego-like block 80/90. If Lego-like block 80/90 does not have an orthogonal surface, then the plane tangent to the first surface which contacts linkage 2E/2F may be suitable as a plane for the origin point, although persons skilled in the art may choose other suitable origin points. The ρ of an exemplary integrated linkage 2E or weld linkage 2F may the same or similar to that of an exemplary linkage 2 with the exception that block 80/90 necessarily will be involved in the pose. In other words, blocks 80/90, like an elaborate face coating 2C/2D are one with the linkage 2E/2F. In an exemplary embodiment, I_M<I_Cfor integrated linkage 2E or weld linkage 2F. According to this exemplary embodiment, the ratio of I_C/I_Mfor an exemplary posable integrated linkage 2E or posable weld linkage 2F may be greater than about 1 but less than about 55.
While exemplary linkages 2 may be illustrated in cross-section and in full by FIGS. 16A-D, FIGS. 18A-D, and FIGS. 19A-D, those skilled in the art will readily understand these illustrations may apply to sections, subsections, ends, or combinations of the same for an exemplary linkage 2 in whole or in part from various vantage points and in any of the other embodiments and interrelated embodiments as disclosed and/or described.
Many further variations and modifications may suggest themselves to those skilled in art upon making reference to above disclosure and foregoing interrelated and interchangeable illustrative embodiments, which are given by way of example only, and are not intended to limit the scope and spirit of the interrelated embodiments of the invention described herein. While many of the exemplary bricks 10/30-90 have been disclosed, these exemplary bricks may be integrated components with other exemplary building blocks and need not exist in isolation. Thus, it is contemplated that the exemplary bricks 10/30-90 and their various surface structures and dimensions may be utilized in conjunction with and as integrated parts of presently available building block systems in addition to functioning on their own.

Claims

1. A toy building block linkage made out of a metal wire and an elastomer coating on the metal wire, the linkage having posability, wherein the posability comprises a ratio of an area moment of inertia of the elastomer coating to the area moment of inertia of the wire being between about 1 and about 50.

2. The system of claim 1, wherein the posability further comprises the area moment of inertia of the elastomer coating being less than 2.821×10⁻⁵in⁴.

3. The system of claim 1, wherein the linkage is integrally coupled to the at least one frictionally-interlocking building block.

4. The system of claim 2, wherein the linkage is integrally coupled to the at least one frictionally-interlocking building block.

5. The system of claim 1, wherein the posabililty further comprises a posability triangle comprising an angle α, an angle β and an angle γ.

6. The system of claim 5, wherein angle β or an angle γ is greater than 90 degrees measured clockwise from the at least one wall.

7. The system of claim 6, wherein only angle β is greater than 90 degrees measured clockwise from the at least one wall.

8. The system of claim 2, wherein the posabililty further comprises a posability triangle comprising an angle α, an angle β and an angle γ.

9. The system of claim 8, wherein angle β or an angle γ is greater than 90 degrees measured clockwise from the at least one wall.

10. The system of claim 9, wherein only angle β is greater than 90 degrees measured clockwise from the at least one wall.

11. The system of claim 3, wherein the posabililty further comprises a posability triangle comprising an angle α, an angle β and an angle γ.

12. The system of claim 11, wherein angle β or an angle γ is greater than 90 degrees measured clockwise from the at least one wall.

13. The system of claim 12, wherein only angle β is greater than 90 degrees measured clockwise from the at least one wall.

14. The system of claim 4, wherein the posabililty further comprises a posability triangle comprising an angle α, an angle β and an angle γ.

15. The system of claim 14, wherein angle β or an angle γ is greater than 90 degrees measured clockwise from the at least one wall.

16. The system of claim 15, wherein only angle β is greater than 90 degrees measured clockwise from the at least one wall.

17. A toy building block and connection kit, comprising:

at least one frictionally-interlocking building block comprising at least one wall and at least one cylindrical stud extending upwardly from the at least one wall; and

a linkage having posability, wherein the posability comprises an area moment of inertia between about 7.4×10⁻⁷in⁴and about 3.2×10⁻⁵in⁴.

18. The toy building block and connection system of claim 17, wherein the area moment of inertia is between about 4.9×10⁻⁶in⁴and about 3.2×10⁻⁵in⁴.

19. The toy building block and connection system of claim 18, wherein the posability further comprises a section modulus of plasticity less than about 1.4000.

20. The toy building block and connection system of claim 19, wherein the posability further comprises a section modulus of plasticity less than about 0.58333.