US20200240132A1

US20200240132A1 - Modular building block system

Info

Publication number: US20200240132A1
Application number: US16/619,166
Authority: US
Inventors: Andre Rocha BARRETO
Original assignee: Fablo International BV
Current assignee: Fablo International BV
Priority date: 2017-06-06
Filing date: 2018-05-31
Publication date: 2020-07-30
Also published as: WO2018226499A1

Abstract

The system and method for the modular construction of three-dimensional structures, and more particularly, to the use of the three-dimensional structures as furniture, storage, and toys. The structures comprise a plurality of panels, rods, and connectors. The structures are made up of one or more inter-connectable blocks. The blocks may have parallel or perpendicular joints. The blocks may be of the same or of different sizes. Numerous accessories are also possible for the modular structures.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional Application Ser. No. 62/515,794, filed Jun. 6, 2017; the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

This invention relates primarily to modular construction structures, and more particularly to their use as furniture, storage, and toys.

BACKGROUND OF THE DISCLOSURE

The technical problem addressed by this invention is that widely used furniture and toys are built for a single purpose and normally discarded when such function is no longer needed. A child's chair, for example, will likely be disposed of or sold when the infant no longer fits the furniture. In addition, voluminous goods often require lots of packaging and space to be shipped to stores or customers. While some modular solutions with compact packaging are available in the market, they often have limitations of use and/or shapes.
One advantage of the system of the present disclosure is that it allows for unlimited applications while at the same time providing aesthetic designs and flat packing. In addition, its modularity, scalability, and simple assembly stimulates creativity and teamwork. The combination of these characteristics makes the system timeless and environmentally friendly, given the building blocks may be used and reused indefinitely. The system of the present disclosure is not a single product but rather a platform, with unlimited possibilities of individual building block design, assembly combinations, and accessories.
The panel and rod construction enables simple or complex three-dimensional structures that are light and easy to manufacture, especially due to the two-dimensional cut of the panels. The system is more flexible than Lego or similar stacking systems. In some cases, the invention enables any planar face of a resultant block to be attached and secured to any face of another block.
Wherefore it is an object of the present disclosure to overcome the above-mentioned shortcomings and drawbacks associated with conventional furniture, storage, and toys.

SUMMARY OF THE DISCLOSURE

One aspect of the present disclosure is a modular building block system comprising a plurality of flat panels, rods, and releasable connectors, for use in building three-dimensional structures. In certain cases, panels include cavities where rods can be attached. In some cases, the combination of two panels and a plurality of rods create hollow three-dimensional blocks. These blocks may be used individually in a plurality of applications, or assembled into larger structures through the use, but not exclusively, of loop connectors or clip connectors.
The system can rely on a kit of parts that can be assembled, disassembled, and reassembled in different ways. One aspect of the present disclosure is a modular building block system comprising at least two flat panels, a plurality of rods, and one or more connectors to assemble into at least one three-dimensional structure.
The at least two panels of the system can include cavities where the plurality of rods can be attached. In some cases, the plurality of rods are fixed to the at least two panels through the use of bolts and inserts, parallel to the longitudinal axis of the plurality of rods. In some cases, the plurality of rods are fixed to the at least two panels through the use of pins, or bolts and inserts, perpendicular to the longitudinal axis of the plurality of rods.
Additionally or alternatively, the system can comprise a combination of two parallel panels and a plurality of rods attached via connectors creates a hollow three-dimensional block. One or more blocks may be used in a plurality of applications.
Additionally or alternatively, the system can comprise the one or more blocks which may be assembled into larger structures through the use, but not exclusively, of loop connectors or clip connectors. Blocks of different sizes and shapes, may be assembled together. The at least two panels of the system can have slots, or openings, cut parallel to each panel edge to enable modular and scalable assembly. Depressions on an external panel surface, together with openings and studs, enable stable block stacking. Openings and depressions follow a standard pattern to enable modular and scalable assembly.
Additionally or alternatively there is provided a modular building block system comprising at least two flat panels, a plurality of rods and one or more connectors to assemble into at least one three-dimensional structure comprising blocks, the system having a standard pattern comprising: a base panel unit having one slot, or opening, in the middle of each base unit panel edge; panels one size increment larger when compared to size of the base unit have a long straight edge that is double the size of the base unit panel edge; panels larger than the base unit include step down openings, aligned with a line of openings included in the base unit; non equilateral panel sizes increase such that the length of the long straight edge is double the length of a panel one size smaller; and openings and depressions in the panels enables stacking with edge-to-edge panel alignment or center-to-center panel alignment.
A planar face of a block may be connected to a planar face of another block according to three possible types of block-to-block connections: panel-to-panel, panel-to-rod and rod-to-rod.
The blocks can comprise different shapes including: equilateral triangular prism; cube; rhombus prism; pentagonal prism; hexagonal prism; octagonal prism; cuboid; trapezoidal prism; parallelepiped prism; kite prism; quarter cylinder; semi-cylinder; cylinder; annulus sector (circular ring) block; quarter elliptical block; semi-elliptical block; elliptical block; and blocks with non-geometrical shape panels. In some cases, blocks with non-geometrical shape panels comprises petals, animal shapes, parts of animal shapes, mandala shapes, oblongs, chevrons, and others.
Studs present at the bottom of one block can fit into depressions and openings on the top of another block. Studs can be an extension of a rod end or disks attached to the panels. Studs can provide clearance protection to panel surfaces, anti-slip capability to blocks, grip and stability to blocks placed on soft surfaces, or a combination thereof.
Additional cavities may be added to panels for rods to be used as spacers between two or more stacked blocks. A plurality of accessories may be attached to the blocks including, but not exclusively: fabric panels; thin flat panels; nets with frames; panel padding; rod padding; rod grips; patterned covers; buttons; wall mounts; and block feet. In some cases, the feet may be screwed on.
These aspects of the disclosure are not meant to be exclusive and other features, aspects, and advantages of the present disclosure will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims, and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features, and advantages of the disclosure will be apparent from the following description of particular embodiments of the disclosure, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure.

FIG. 1A shows a kit of parts according to the principles of the present disclosure.

FIG. 1B shows a resultant small size block assembled from the kit of parts shown in FIG. 1A.

FIG. 2A shows a cross sectional view of two stacked base unit cube blocks according to the principles of the present disclosure, with parallel joints.

FIG. 2B shows a detail view as shown in FIG. 2A.

FIG. 2C shows a detail view as shown in FIG. 2A.

FIG. 3A shows a kit of parts according to the principles of the present disclosure.

FIG. 3B shows a resultant medium size block assembled from the kit of parts as shown in FIG. 3A.

FIG. 4 shows a cross sectional view of a medium cube block according to the principles of the present disclosure, with parallel joints, on an inclined plane, kept stable by the friction between the stud and the plane.

FIG. 5A shows a cross sectional view of two stacked medium cube blocks according to the principles of the present disclosure, with parallel joints, on top of an irregular and soft surface.

FIG. 5B shows a detail view as shown in FIG. 5A.

FIG. 5C shows a detail view as shown in FIG. 5A.

FIG. 6A shows a cross sectional view of two stacked medium cube blocks, according to the principles of the present disclosure, with perpendicular joints, on top of an irregular surface.

FIG. 6B shows a detail view as shown in FIG. 6A.

FIG. 6C shows a detail view as shown in FIG. 6A.

FIG. 7A shows a standard pattern applied to various sized panels enabling alignment and stacking of different size panels according to the principles of the present disclosure.

FIG. 7B shows an asymmetrical rod having different end portions according to the principles of the present disclosure.

FIG. 8 shows different combinations of stacked blocks of various sizes, where combined height matches the size of a medium size cube according to the principles of the present disclosure.

FIG. 9 shows examples of equilateral medium size blocks according to the principles of the present disclosure.

FIG. 10 shows examples of non-equilateral medium size blocks according to the principles of the present disclosure.

FIG. 11 shows examples of non-geometrical panel shapes according to the principles of the present disclosure.

FIG. 12 shows examples of three types of block-to-block connections: panel-to-panel, panel-to-rod, and rod-to-rod according to the principles of the present disclosure.

FIG. 13 shows examples of accessories for certain blocks of the present disclosure.

FIG. 14 shows a medium cube block according to the principles of the present disclosure providing stacking compatibility a smaller block through grooves.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring first to FIGS. 1A and 1B, one example of a kit of parts and a resulting assembled block according to the principles of the present disclosure are respectively shown in these figures. More specifically, FIG. 1A shows a basic kit of parts for assembling a base unit (small) cube block. According to the system of the present disclosure, simple elements can be easily manufactured and combined with one another to form complex structures.
The kit of parts comprises flat panels which typically are planar pieces of board made of one or a combination of flat materials such as wood, plywood, laminates, polymers, and the like. Each of the flat panels 1 provides a working surface for the system. As generally shown, each one of the flat panels 1 include circular holes 26 located adjacent each of the four corner areas of each flat panel 1, and the circular holes 26 extend completely through the flat panel 1. Each circular hole 26 serves to secure a respective rod 2 to the flat panel 1, as discussed below. Each circular hole 26 is spaced a small distance, e.g., 0.5 to 1 inch or so, from both of the adjacent side edges of the flat panel 1. Each flat panel 1 further comprises a pair of openings 25 in the center of the panel that can be used to secure one panel to another panel when in a stacked arrangement, which will be discussed in more detail, below.
On a first side of the flat panel 1, the circular hole 26 is counter sunk (see the lower panel 1 in FIG. 1A) so as to form a depression d or cavity which receives a first end of a respective rod 2. The opposite side of the flat panel 1 has smaller sized hole (see the upper panel 1 in FIG. 1A), which is generally concentric with the depression or cavity, on the opposite side of the panel 1, and is sized to permit a threaded end of a threaded fastener 3 to pass therethrough and engage with the respective rod 2, but prevent the head of the threaded fastener 3 from passing through the smaller sized hole.
As shown in FIGS. 2A, 2B and 2C, a central portion of each end of the rod 2 may have a bore which is sized to captively receive and retain an insert 4, manufactured from metal or plastic, for example, within the bore. The insert 4 has an internal threaded bore which is sized to matingly receive and engage with a threaded end of a threaded fasteners or bolt 3. The metallic insert 4 may be glued or otherwise permanently secured inside the bore to permanently retain the insert 4 within the bore. In addition, each opposed end of one of the rods 2 typically has a slightly reduced diameter which is sized and shaped so as to fit into and be received by the depression or cavity formed in the first side of the panel 1. In some cases, the larger diameter of the rod 2 forms a shoulder which abuts against the first side of the panel 1 and thus prevents further insertion of the rod 2 into the depression or cavity in the panel 1. After the reduced diameter of the leading end of the rod 2 is closely received within the depression or cavity of the panel 1, a threaded fastener 3 then passes through the smaller sized hole, located on the opposite side of the panel 1, and engages with the threaded bore of the insert 4, retained within the end of the rod 2, to secure the rod 2 to the panel 1. Each one of the remaining three rods 2 is connected to the panel 1, in the other three corner areas of the panel 1, in a similar manner.
Thereafter, the respective depressions or cavities, formed in the first side of the second panel 1, receive and engage with the respective opposite ends of each one of the four rods 2, in a similar manner. Lastly, a respective threaded fastener 3 then passes through the respective smaller sized hole, located on the opposite side of the panel 1, and engages with the respective with the threaded bore of the insert 4, retained within the respective ends of the rods 2, to connect each one of the rods 2 to the panel 1 and complete assembly of the small size block 14, as shown in FIG. 1B.
Still referring to FIGS. 1A and 1B, each one of the panels 1 for the base unit includes one centrally located slot 21 which is along each side edge of the panel 1 equally spaced from the two adjacent corner areas of the panel 1. Depending upon the actual size of the panel, each one of side edges of the panel 1 may have one, three, or seven openings, for example, or any other desired number of openings, formed along each side edge of the panel 1. Each slot extends parallel to the side edge of the panel 1 and is typically spaced between about 0.25 inches and about 1 inch or so from the side edge.
As diagrammatically shown in FIG. 12, a coupling member, such as a strap 11 or a clip 12, can be passed through a pair of overlapped and aligned openings to facilitate releasable coupling of the two adjacent or abutting panels 1 together with one another (see FIG. 12), as will be described below in further detail below. As generally shown in FIG. 7A, for example, each one of the openings, formed along a side edge of a panel 1, are axially aligned with one another (See, e.g., 21, 22, 24).
As shown in FIGS. 2A, 2B, and 2C, and 5A, 5B and 5C, preferably the thickness of each panel 1 is sufficiently thick, e.g., between 0.75 and 1.5 inches, so that the small hole, which receives and engages with the head of the fastener or bolt 3, is deep enough so that the head of the fastener or bolt 3, once secured to a respective rod 2, is recessed within the small hole and thus provides space for receiving substantially ½ of a disc 7 while substantially the remaining other ½ of the disc 7 may be received within the small hole of the overlapped and adjacent panel 1, as shown in FIGS. 2B and 5B, or engage with a textured surface, as shown in FIG. 2C, FIG. 4, and 5C, to prevent, or minimize at the very least, any relative movement between the two three-dimensional blocks 14 or the three-dimensional block 14 and the mating supporting surface.
It is to be appreciated that the panels may have any geometric or other two-dimensional shapes as shown, for example, in FIGS. 9, 10, and 11. With the advent of Computer Numerical Control routers, the panels can be easily cut from a standard sheet of material in large scale. In some cases, one blank sheet may be cut into panels of the same shape or mixed shapes.
Referring to FIGS. 1B and 3B, rods 1 work like columns or legs, to connect panels 1 together with minimum volume. The format of the rod ends (“male”) match those of the panel cavities (“female”). Rods provide height and strength to the resulting three-dimensional blocks 14. For some applications, the length of the rods 2 may be increased so as to space the two panels 1 further away from one another, e.g., the resulting three-dimensional blocks 14 is “taller,” while for other applications, the length of rods 2 may be shortened to so that the two panels 1 are spaced closer to one another, e.g., the resulting three-dimensional blocks 14 is “shorter.”
Studs may be an extension of a rod end 6 or separate disks 2 may be inserted into the panel depressions. In some cases, studs fit into the openings and depressions, providing alignment for stacked panels. In addition, studs provide protection to lower panels by keeping a clearance distance from the surface below the block 3. Studs may also provide grip to soft surfaces 4 and anti-slip capability 5 to the block. See, for example, FIG. 4 where a cross sectional view of a medium cube block according to the principles of the present disclosure, with parallel joints, on an inclined plane, is shown being kept stable by the friction between the stud and the plane.
As shown in the figures, the system of the present disclosure comprises panels, rods and connectors. When disassembled, these form a compact package, reducing the associated packaging and transportation costs. When assembled together, they enable hollow three-dimensional blocks that are strong and lightweight, which can be used for multiple applications.
Referring to FIG. 2A, a cross sectional view of two stacked base unit cube blocks according to the principles of the present disclosure, with parallel joints of FIGS. 1A and 1B is shown. FIG. 2B shows an enlarged view of area 2B in FIG. 2A and FIG. 2C shows an enlarged view of area 2C of FIG. 2A. More specifically, releasable connectors may be used. In some cases, bolts 6 and inserts 7 secure the connection between a rod 2 and a panel 1. Threaded inserts 4 may be fastened in holes in the ends of rods 2. In another case, bolts 3 are tightened parallel to the rod axis. When the bolts 3 are released, the blocks can be disassembled.
In the system of the present disclosure, rods are connected to panels with two possible types of joints. In some cases, each block will have only one type of joint, depending on the choice of panel material and application. Joints can be assembled, disassembled, and reassembled repeatedly and indefinitely. For both types of joints, rod ends may either be cylindrical with smaller diameter, or tapered.
Referring first to FIGS. 3A and 3B, a kit of parts and a resulting assembled medium block according to the principles of the present disclosure are respectively shown in these figures. More specifically, FIG. 3A shows a basic kit of parts for assembling an equilateral medium cube block. According to the system of the present disclosure, simple elements can be easily manufactured and combined with one another to form complex structures.
The kit of parts comprises flat panels which typically are planar pieces of board made of one or a combination of flat materials such as wood, plywood, laminates, polymers, and the like. Each of the flat panels 1 provides a working surface for the system. As generally shown, each one of the flat panels 1 include circular holes 26 located adjacent each of the four corner areas of each flat panel 1, and the circular holes 26 extend completely through the flat panel 1. Each circular hole 26 serves to secure a respective rod 2 to the flat panel 1, as discussed below. Each circular hole 26 is spaced a small distance, e.g., 0.5 to 1 inch or so, from both of the adjacent side edges of the flat panel 1. Additionally, there are holes 27 located on the panel for the medium block that are spaced to interact with the corner holes in a small base unit block, for example (See, e.g., 26 in FIG. 1A).
On a first side of the flat panel 1, the holes are counter sunk (see the lower panel 1 in FIG. 3A) so as to form a depression d or cavity which receives a first end of a respective rod 2. The opposite side of the flat panel 1 has smaller sized hole (see the upper panel 1 in FIG. 3A), which is generally concentric with the depression or cavity, on the opposite side of the panel 1, and is sized to permit a threaded end of a threaded fastener 3 to pass therethrough and engage with the respective rod 2, but prevent the head of the threaded fastener 3 from passing through the smaller sized hole.
As shown in FIGS. 2A, 2B and 2C, a central portion of each end of the rod 2 may have a bore which is sized to captively receive and retain an insert 4, manufactured from metal or plastic, for example, within the bore. The insert 4 has an internal threaded bore which is sized to matingly receive and engage with a threaded end of a threaded fasteners or bolt 3. The metallic insert 4 may be glued or otherwise permanently secured inside the bore to permanently retain the insert 4 within the bore. In addition, each opposed end of one of the rods 2 typically has a slightly reduced diameter which is sized and shaped so as to fit into and be received by the depression or cavity formed in the first side of the panel 1. In some cases, the larger diameter of the rod 2 forms a shoulder which abuts against the first side of the panel 1 and thus prevents further insertion of the rod 2 into the depression or cavity in the panel 1. After the reduced diameter of the leading end of the rod 2 is closely received within the depression or cavity of the panel 1, a threaded fastener 3 then passes through the smaller sized hole, located on the opposite side of the panel 1, and engages with the threaded bore of the insert 4, retained within the end of the rod 2, to secure the rod 2 to the panel 1. Each one of the remaining three rods 2 is connected to the panel 1, in the other three corner areas of the panel 1, in a similar manner.
Thereafter, the respective depressions or cavities, formed in the first side of the second panel 1, receive and engage with the respective opposite ends of each one of the four rods 2, in a similar manner. Lastly, a respective threaded fastener 3 then passes through the respective smaller sized hole, located on the opposite side of the panel 1, and engages with the respective with the threaded bore of the insert 4, retained within the respective ends of the rods 2, to connect each one of the rods 2 to the panel 1 and complete assembly of the block 14, e.g., an equilateral medium size as shown in FIG. 3B.
Still referring to FIGS. 3A and 3B, each one of the panels 1 for the equilateral medium block includes one centrally located slot 21 which is along each side edge of the panel 1 equally spaced from the two adjacent corner areas of the panel 1. Depending upon the actual size of the panel, each one of side edges of the panel 1 may have one, three, or seven openings, for example, or any other desired number of openings, formed along each side edge of the panel 1. Each slot extends parallel to the side edge of the panel 1 and is typically spaced between about 0.25 inches and about 1 inch or so from the side edge. Here, the medium panel has three openings along each edge.
As shown for example in FIGS. 2A-2C and FIGS. 5A-5C a parallel joint 8 is used. There, for each rod, a panel has a pilot hole through its thickness and the center of the hole is aligned with the longitudinal axis of the rod. A hole with its center aligned with the center of the pilot hole is added to create the cavity for each rod. In some cases, the two ends of a rod will have a reduced diameter, compared to the remainder of the rod, such as a taper, to fit in a panel counter-bored hole. On the external face of the panel, for each rod, another set of counter-bored holes may be present to enable bolts to be fastened into the inserts and still provide clear working surface. In addition, the external counter-bored holes may serve as depressions where studs from other blocks can couple, and disk studs may be inserted.
Parallel joints may require separate disk studs to be added to the lower panels. This construction is advantageous because disks can be made with materials such as rubber or silicone. Parallel joints are particularly useful for panels with laminated materials such as plywood, thus keeping plies under compression.
Referring to FIG. 5A, a cross sectional view of two stacked medium size cube blocks according to the principles of the present disclosure, with parallel joints, on top of an irregular and soft surface is shown. FIG. 5B shows a detail view of area C, as shown in FIG. 5A, and FIG. 5C shows a detail view of area D, as shown in FIG. 5A.
As shown for example in FIGS. 6A-6C, a perpendicular joint 32 is used. FIG. 6A shows a cross sectional view of two stacked medium cube blocks, according to the principles of the present disclosure with perpendicular joints, on top of an irregular surface. FIG. 6B shows a detail view as shown in FIG. 6A, and FIG. 6C shows a detail view as shown in FIG. 6A. There, the perpendicular joint offers a coupling between rods and panels which is similar to the parallel joint, but with the following differences. For each rod, a panel has pilot holes located perpendicular to the longitudinal axis of the rod. Each rod end has holes perpendicular to its longitudinal axis and aligned with the pilot holes of the panel. In some cases, a perpendicular joint requires fewer components and is easier to assemble. This joint enables the possibility of using the rod end 6 as a stud. Rings or sleeves may be added between the rod end and the panel cavity to compensate for dimensional variances due to environment conditions such as temperature and humidity. In some cases, pins 9 are an alternative to bolts when securing the connection between a road and a panel. Pins 5 may inserted through holes on rods and panels, which are perpendicular to the rod axes. When the pins are released, the blocks can be disassembled.
Still referring to FIG. 6A, a 3-D block 10 is defined as the combination two parallel panels, connected by a plurality of rods. The connection between a panel and a rod is secured by bolts or pins in two possible types of joints, as discussed above. A typical product package includes the required elements to build one block. See, FIGS. 1A and 3A, for example.
Referring to FIG. 7A, a standard pattern enabling alignment and stacking of different sizes of panels according to the principles of the present disclosure is shown. More specifically, standard sizes and panel patterns provide modularity and scalability to the system. The system is composed of sets of blocks grouped by size, where groups are defined by the flat panel dimensions.
A base unit 15 is the smallest building element of the system. In an equilateral medium size panel 16 has adjacent side edges which each have double the length of the adjacent edges of the panel of the base unit 15. Accordingly, the size or area of the medium size panel 16 is substantially four times the area or size of the base unit 15. In non-equilateral medium size panel 11 (see the panel at the far left in FIG. 7A) will have only one longer side edge that is double the length of the edge of the base unit panel 15 while the adjacent (shorter) side edge of the non-equilateral medium size panel 17 will have the same length as the edge of a base unit panel 15. Accordingly, the size or area of the non-equilateral medium size panel 12 is substantially twice the area or size of the base unit 15, and substantially half the area or size as the equilateral medium size panel 16.
Still referring to FIG. 7A, an equilateral large size panel 18 has adjacent side edges which each have double the length of each of the adjacent side edges of the equilateral medium unit panel 16. Accordingly, the size or area of the equilateral large size panel 18 is substantially four times the area or size of the medium size panel 16. In a non-equilateral large size panel (not shown) would have only one longer side edge that is double the length of the edge of the medium size panel 16 while the adjacent (shorter) side edge of the non-equilateral large size panel would have the same length as the edge of the medium size panel 16. Accordingly, the size or area of the non-equilateral large size panel is substantially twice the area or size of the medium size panel 15. In some cases, the system can grow indefinitely, where the next size increment up will always have its long edge double the length of the long edge of the next size smaller.
In some cases, the base unit panel 15 will have one slot 13 located along the middle of each straight side edge thereof. In an equilateral medium panel 16 will have on each straight edge, in addition to the middle slot 22, or two step-down openings aligned to the openings of two base unit panel edges. The center of the step down openings will therefore be positioned a quarter of the length of the panel from the closest edge. The medium size panel with have a total of three openings 14 located along each straight edge, but spaced a small distance inwardly therefrom. Each flat panel will have an additional pair of openings 25 that are located in the center of the panel.
Still referring to FIG. 7A, the non-equilateral medium panel 17 will have on each of its shorter straight edges one slot in the middle, aligned with the slot of a base unit 21. On its long straight edges, in addition to the middle slot, a non-equilateral medium panel will have two step down openings 23 aligned with the openings of two base unit panel edges. The center of step down openings will therefore be positioned a quarter of the length of the panel from the closest edge. The non-equilateral medium size panel 17 will therefore have three openings 15 per longer straight edge.
In some cases, an equilateral large panel 18 will have one slot in the middle of its edge 24 and step down openings for medium and base unit sizes. The equilateral large size panel 18 will therefore have a total of seven openings 16 on each straight edge. The system can grow indefinitely where, for each straight edge of a given size, the number of openings of the panel size will always be double the number of openings of the predecessor, plus one. For all sizes, two parallel openings equally spaced from the center of the panel 25 may be optionally added, to enable two blocks to be secured with a single releasable connector.
Still referring to FIG. 7A, each block will include holes 17 on the corners of the external face of panels to serve as depressions for studs, as well as to sink bolt heads providing a clear working surface. For medium and subsequent sizes, holes (e.g., 27) matching the center of the axis of each base unit rod axis may be optionally added to enable a base unit block to be stacked on its top with center alignment. On the medium size panels 16 there is only one set of these holes in the center 18. In some cases, the large and subsequent sizes follow repetitions of the medium panels. In addition to the edge and center openings, a large size equilateral panel may include internal openings 19 to replicate exactly the pattern of the medium sized blocks. The system can grow indefinitely where, starting from the medium panel, the next size will always include repetitions of the pattern of its predecessor.
Still referring to FIG. 7A, one aspect of the combination of openings and depressions, which provide cavities where the studs fit inside, enable blocks to be stacked in a variety of combinations. Two types of stacking alignment include center-to-center 29 and edge-to-edge 30. In some cases, center-to-center 29 provides alignment of the center of one panel with the center of another panel. In the case when two blocks are of the same size, studs will fit into the depressions aligned with the rod centers. In the case that a base unit is stacked on top of a medium sized panel, for example, studs will fit inside the matching depressions. In the case that a medium unit is stacked on top of a large panel, for example, studs will fit in the corresponding openings. In some cases, edge-to-edge 30 provides alignment of the edge of a panel with the edge of another panel. With this configuration, for example, up to four base unit blocks may be stacked on top of a medium sized cube. Similarly, up to four medium sized cubes may be stacked on top of a large equilateral panel.
Referring to FIG. 7B, an asymmetrical rod having different end portions according to the principles of the present disclosure is shown. More specifically, a rod 2 will have a length L and when a rod end 6 is to be used as a stud the rod end will be dimensioned to have a length (L₆) such that it will pass through the entire thickness of a flat panel and protrude or extend some distance beyond a far surface of the panel so that the rod end 6 can act as a stud. Thus, an opposed end 6′ of the asymmetrical rod will have a length (L_6′) that is dimensioned to be less than the thickness of a flat panel such that the opposed end 6′ of the asymmetrical rod will only partially extend into a hole and abut with a rod end 6 of an adjacent 3D block 14. See, e.g., FIGS. 6A-6C.
Referring to FIG. 8, different combinations of stacked blocks of various sizes, having combined height that match the size of a medium size cube according to the principles of the present disclosure are shown. More specifically, the height of a block will follow multiples or fractions of the base unit (smallest block) which enables stacking combinations in any position. For example, two layers of four base unit cubes having base unit panels 15 can be stacked to match the size of a medium unit block 20. Another example would be four blocks with heights corresponding to half of the length of the base unit, could have a total stack size of a medium unit block 21. It is understood that the dimensions of the many flat panels (e.g. 15, 16, 17, 18) coupled with varying length rods 2 provide for a variety of combinations of 3D blocks that occupy the same volume.
Referring to FIG. 9, examples of equilateral medium size blocks according to the principles of the present disclosure are shown. More specifically, a plurality of three-dimensional shapes may be created within the same system. In some cases, equilateral blocks are used. An equilateral triangular prism (33) will include two equilateral triangular panels, three rods (one at each vertex of the panel) and optional connectors. A cube (34) will include two square panels, four rods (one at each vertex of the panel) and optional connectors. A rhombus prism (35) will include two rhombus (diamond) panels, four rods (one at each vertex of the panel) and optional connectors. A pentagonal prism (36) will include two pentagonal panels, five rods (one at each vertex of the panel) and optional connectors. A hexagonal prism (37) will include two hexagonal panels, six rods (one at each vertex of the panel) and optional connectors. An octagonal prism (38) will include two octagonal panels, eight rods (one at each vertex of the panel) and optional connectors.
Referring to FIG. 10, examples of generic (non equilateral) medium size blocks according to the principles of the present disclosure are shown. More specifically, a cuboid (39) will include two rectangular panels, four rods (one at each vertex of the panel) and optional connectors. A trapezoidal prism (40) will include two trapezoid panels, four rods (one at each vertex of the panel) and optional connectors. A parallelepiped prism (41) will include two parallelogram panels, four rods (one at each vertex of the panel) and optional connectors. A kite prism (42) will include two kite panels, four rods (one at each vertex of the panel) and optional connectors. A quarter cylinder (43) will include two quarter circle panels, three rods (one at each vertex of the panel) and optional connectors. A semi-cylinder (44) will include two semi-circular panels, three rods (one at each vertex of the panel, and one opposite to the middle of the straight edge) and optional connectors. A cylinder (45) will include two circular panels, four rods (equally distributed) and optional connectors. An annulus sector (circular ring) block (46) will include two annulus sector panels, four rods (one at each vertex of the panel) and optional connectors. A quarter elliptical block (47) will include two quarter elliptical panels, three rods (one at each vertex of the panel) and optional connectors. A semi-elliptical block (48) will include two semi-elliptical panels, three rods (one at each vertex of the panel, and one opposite to the middle of the straight edge) and optional connectors. An elliptical block (49) will include two elliptical panels, four rods (equally distributed on both axes) and optional connectors.
Referring to FIG. 11, examples of non-geometrical panel shapes according to the principles of the present disclosure are shown. More specifically, in some cases, non-geometrical will include two identical two-dimensional shape panels, three or four rods, and optional connectors. Some examples include, but are not limited to, petals (22), animal shapes (23), parts of animal shapes (24), mandala shapes (25), and oblongs, chevrons and others (26). As noted herein, a standard pattern of openings cut in the panels, parallel to its edges, enables two blocks to be firmly secured together through the use of releasable connectors such as, but not exclusively, loop connectors and clip connectors.
Referring to FIG. 12, examples of three types of block-to-block connections: panel-to-panel, panel-to-rod, and rod-to-rod according to the principles of the present disclosure are shown. More specifically, modularity at the block assembly level is possible. In some cases, the system provides for the possibility of firmly securing any planar face of a block connected to any planar face of another block.
Panel-to-panel 27 connections may be made. There, two blocks can be secured together when the external face of their panels are united by releasable connectors 11, 12 passing through their openings. Another way to connect via panel-to-panel is when two panels placed side by side are secured with connectors.
Panel-to-rod 28 connections may be made. There, the versatility of loop connectors enables blocks in alternate positions, one with horizontal panels and other with vertical panels, to be secured together. In this configuration a loop connector or clip connector may embrace the slot of a panel of a first block and a rod of a second block.
Rod-to-rod 29 connections may be made. There, the connection can be achieved by the use of loop connectors, which will embrace two or more rods, leaving a clear working surface on the panels. Another advantage of this connection is that a single loop can embrace rods of several blocks.
Interchangeability of components is provided. There, rods and panels are interchangeable within each block size group. All base unit blocks have the same diameter of rod ends, bolts, pins and inserts. The same is true of all medium blocks, and within each of the subsequent size groups. This feature enables the builder to disassemble blocks and reassemble in a plurality of combinations. The feature also enables builders to acquire stand-alone parts in the aftermarket and create new three-dimensional blocks with different height and/or shape. In some cases, additional counter-bored or tapped holes be may be added to panels so that rods can be used as spacers between two stacked blocks.
Hook and loop connectors 11 can provide the flexibility of connecting a plurality of combinations of panels and boards. An example of a hook and loop connector is a hook and loop cinch strap. In some cases, the loop connector can embrace openings and rods at different positions, and of different sizes, similarly to a waist belt. Loops can be tied and released indefinitely.
Clip connectors 12 are an alternative to loop connectors. Clip connectors may be U shaped thin parts with curved ends. One common application of clips is securing panel-to-panel connections, where one leg of the clip is inserted into the slot of a panel and the other leg is inserted into the slot of a second panel 13. See, for example, FIG. 12, where examples of three types of block-to-block connections: panel-to-panel, panel-to-rod, and rod-to-rod according to the principles of the present disclosure are shown.
In some cases, the curved ends of the clip connector 12 embrace the edge of the slot keeping the clip stable. Another application of clip connectors 12 is in securing one block stacked on top of another block, where each leg of the clip embraces one of the center openings 25 of both blocks. In some cases, clip connectors 12 can be released with a slight bend of its legs and pushed out of the openings. One advantage of the clip connector 12 is having a design that can be easily manufactured with stamped metals or other materials.
Referring to FIG. 13, examples of accessories for certain blocks according to the principles of the present disclosure are shown. More specifically, a plurality of accessories is possible. In some cases, the design of a block, including panels with openings and rods, enables a plurality of accessories to be attached. Some examples include, but are not limited to, fabric panels 30 comprising pieces of fabric with laces that can be employed to close the open faces of the blocks, where features enabled by this accessory include creation of tunnels, walls and windows; thin panels 31 made of flat materials such as cardboard and laminates, with openings that follow the system pattern, enable creation of tunnels, walls and windows, where the panels may be illustrated to add educational or recreational functionality to the blocks and assemblies; nets with frames 32 can be attached to blocks to provide safety and keep things within the boundaries of a panel, without losing visibility and lightweight of the system; panel padding 33 made of soft materials, embraces the panel and provides impact protection to panels as well as to people and other objects interacting with the system; rod padding 34 made of soft materials covers the surface of the rods providing impact protection to rods as well as to people and other objects interacting with the system; rod grips 35 comprise hollow cylinder sleeves to cover parts of the rod and provide a better grip than the rod material alone; a panel cover 36 is a flat piece of thin material that can be attached, or glued on the panel surface to cover the openings for a clear working surface or to add an illustration; and buttons 37 are two disks connected by a small shaft which slide in the panel slot. In some cases, wall mounts 38 may be “J” shaped metal parts, where the curved part of the mount hooks into the panel slot and the straight face has two or more holes so mounts can be screwed into a wall or the like. Lastly, feet 39 may be added. Feet are similar to studs. In some cases, detachable feet 67 provide panel surface clearance protection, grip to soft surfaces, and anti-slip capability to the block. Different lengths of feet can be used to adjust the total height of a block or a stack of blocks.
Referring to FIG. 14, a medium cube block according to the principles of the present disclosure providing stacking compatibility to smaller blocks through grooves is shown. More specifically, grooved panels enable backwards compatibility with blocks smaller than a base unit of a given size family. Concentric depressions with the same shape of the panel perimeter enable stacking by providing coupling space for studs of smaller blocks placed on top of the grooved panel. The distance between center lines of the grooves may align with the center distance between the studs of blocks with half 72 or a quarter 73 of the size of a base unit.
While various embodiments of the present invention have been described in detail, it is apparent that various modifications and alterations of those embodiments will occur to and be readily apparent to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the appended claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various other related ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items while only the terms “consisting of” and “consisting only of” are to be construed in a limitative sense.
The foregoing description of the embodiments of the present disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Although operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results.
While the principles of the disclosure have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the disclosure. Other embodiments are contemplated within the scope of the present disclosure in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present disclosure.

Claims

1. A modular building block system comprising:

at least two flat panels,

a plurality of rods,

each panel having a pattern comprising a plurality of cavities and a plurality of openings, each of the cavities being sized for matingly receiving one end of the plurality of rods and each of the openings being sized for receiving a connector,

a plurality of fasteners for securing an end of the plurality of rods to one of the panels to facilitate assembly into at least one three-dimensional structure, and

at least one connector for connecting the three-dimensional structure with another three-dimensional structure.

2. The system of claim 1, wherein the plurality of rods are fixed to the at least two panels through the use of bolts and inserts, parallel to the longitudinal axis of the plurality of rods.

3. The system according to claim 1, wherein the plurality of rods are fixed to the at least two panels through the use of pins, or bolts and inserts, perpendicular to the longitudinal axis of the plurality of rods.

4. The system according to claim 2, wherein the combination of two parallel panels and a plurality of rods attached, via connectors, creates a hollow three-dimensional block.

5. The system according to claim 2, wherein one or more blocks may be used in a plurality of applications.

6. The system of claim 5, wherein the one or more blocks may be assembled into larger structures through the use, but not exclusively, of loop connectors or clip connectors.

7. The system according to claim 5, wherein blocks of different sizes and shapes, may be assembled together.

8. The system according to claim 1, wherein the at least two panels have openings cut parallel to each panel edge to enable modular and scalable assembly.

9. The system according to claim 1, wherein depressions on an external panel surface, together with openings and studs, enable stable block stacking.

10. The system according to claim 4, wherein openings and depressions follow a standard pattern to enable modular and scalable assembly.

11. A modular building block system according to claim 1, comprising at least two flat panels, a plurality of rods and one or more connectors to assemble into at least one three-dimensional structure comprising blocks, the system having a standard pattern comprising:

i. a base panel unit having one slot in the middle of each base unit panel edge;

ii. panels one size increment larger when compared to a size of the base unit have a long straight edge that is double the size of the base unit panel edge;

iii. panels larger than the base unit include step down openings, aligned with a line of openings included in the base unit;

iv. non-equilateral panel sizes increase such that the length of the long straight edge is double the length of a panel for one size smaller; and

v. openings and depressions in the panels enables stacking with edge-to-edge panel alignment or center-to-center panel alignment.

12. The system of claim 11, wherein a planar face of a block may be connected to a planar face of another block according to three possible types of block-to-block connections: panel-to-panel, panel-to-rod and rod-to-rod.

13. The system of claim 11, wherein the blocks comprise different shapes including:

i. an equilateral triangular prism;

ii. a cube;

iii. a rhombus prism;

iv. a pentagonal prism;

v. a hexagonal prism;

vi. an octagonal prism;

vii. a cuboid;

viii. a trapezoidal prism;

ix. a parallelepiped prism;

x. a kite prism;

xi. a quarter cylinder;

xii. a semi-cylinder;

xiii. a cylinder;

xiv. an annulus sector (circular ring) block;

xv. a quarter elliptical block;

xvi. a semi-elliptical block;

xvii. an elliptical block; and

xviii. blocks with non-geometrical shape panels.

14. The system of claim 13, wherein blocks with non-geometrical shape panels comprises petals, animal shapes, parts of animal shapes, mandala shapes, oblongs, chevrons, and others.

15. The system according to claim 1, wherein studs present at the bottom of one block fit into depressions and openings on the top of another block.

16. The system of claim 15, wherein studs are an extension of a rod end or disks attached to the panels.

17. The system of claim 15, wherein studs provide clearance protection to panel surfaces, anti-slip capability to blocks, grip and stability to blocks placed on soft surfaces, or a combination thereof.

18. The system according to claim 1, wherein additional cavities may be added to panels for rods to be used as spacers between two or more stacked blocks.

19. The system according to claim 1, wherein a plurality of accessories may be attached to the blocks including, but not exclusively:

i. fabric panels;

ii. thin flat panels;

iii. nets with frames;

iv. panel padding;

v. rod padding;

vi. rod grips;

vii. patterned covers;

viii. buttons;

ix. wall mounts; and

x. feet.