WO2006136835A1

WO2006136835A1 - Component for a constructional toy

Info

Publication number: WO2006136835A1
Application number: PCT/GB2006/002294
Authority: WO
Inventors: Hisao Sato
Original assignee: Hisao Sato
Priority date: 2005-06-23
Filing date: 2006-06-22
Publication date: 2006-12-28
Also published as: GB2427371B; GB2427371A; GB0512855D0

Abstract

A child's constructional toy or a kit of parts for constructing a toy or model comprises a set of components such as (A) and (B) formed from a laminate material with at least three layers, each of the outermost layers (1) and (2) being of a flexurally resistant material such as wood and each bonded to a respective surface of an inner layer (2) being of a compressibly resilient material such as a closed cell foam material, the components being made to interengage using a slotted or recessed arrangement (4) in one component (B) whereby the other component (A) can be fitted edge-wise into the slot (4) by a slight compression applied between the outer layers of the component (A) . The slot width (W) of the component (B) is marginally narrower than the uncompressed width (X) of the component (A) whereby after such engagement the restoration of the width (X) provides retention.

Description

COMPONENT FOR A CONSTRUCTIONAL TOY

Field of the Invention This invention relates primarily to a component for a constructional toy, particularly a child's constructional toy, wherein a number of such components may be assembled together by engagement of one component with another component to enable a structure to be built-up.

In a broader aspect this invention relates to the construction of a component forming part of a kit enabling similar components to be assembled into a larger construction by engagement of the components in a manner which provides a firm and stable connection between the components whilst also permitting ready disassembly when required and without using extraneous coupling parts.

In a further and yet broader aspect this invention relates generally to a laminate construction and method of making same, particularly to form a panel.

Summary of the invention In accordance with this invention there is provided a constructional component having at least three layers, each of the outermost layers being of a more rigid and less compressible material than an inner layer, each outer layer being bonded to an inner layer. The inner layer may be a sheet of material. Alternatively, the inner layer may comprise discrete areas of material each spaced from one another.

This invention also provides a constructional component part for use in combination with other component parts, said component part being capable of interengagement with another component part, the component part being formed from at least three layers, each of the outermost layers being of a flexurally resistant and substantially uncompressible material and each bonded to an inner layer being of a compressibly resilient material.

This invention also relates to a method of manufacturing a laminate material primarily, but not essentially, for a constructional component, the material having at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to a respective surface of an inner layer being of a compressibly resilient material, the method comprising: i. coating one surface of each outer layer or both surfaces of an inner layer, or all such surfaces, with an adhesive; ii. bringing said surfaces into face to face contact; applying pressure across the outer layers; iii. maintaining the pressure for a time to achieve an adhesive bond between the surfaces; iv. removing the pressure; and optionally v. shaping the laminate to form a component.

The outermost layers may comprise a stiff or rigid material such as wood, wood substitute or a plastics material. Such material forms the basic structural shape of the component and provides stability and the desired surface properties. The inner layer or layers may comprise a foam material, particularly a closed cell foam material, or a rubber or elastomer material. The construction permits limited movement of the outermost layers when subject to compressive loading.

The layers are bonded together at their mating surfaces using an adhesive agent applied preferably over the whole of such mating areas. This invention also provides a set of such constructional component parts wherein one part at least in the set includes a slot or recess disposed transversely to an edge of the laminate, the width of the slot or recess being less than the uncompressed thickness of another component part of the set, such that the other part may be located in the slot of the one part by compressive force applied across the outer layers of said part reducing the thickness through compression of the resilient material, removal of the compressive force allowing restoration of the compressive material to retain the other part within the recess of the one part.

For a child's constructional toy, or indeed a kit of parts for constructing models or the like, some, or all, component parts may be fabricated from the laminate of this invention. Parts may be made to inter-engage using a slotted or recessed arrangement in one part whereby one part can be fitted edge-wise into the slot of another part by a slight compression applied between the outer layers of the one part. The slot of the other part being marginally narrower than the uncompressed width of the one part. Thus after such engagement the restoration of the width of the one part ensures retention.

More than three layers may be provided in such a case one or more inner layers of flexurally resistant material is bonded at each side to a compressibly resilient material which, in turn, are bonded to the outer layers or further inner layers.

In this invention the layers will preferably comprise laminar sheets of the relevant material.

In a modified construction the outer layers may have a characteristic imparting rigidity and with a compressibility which is significantly less than that of the foam inner layer.

Brief Description of the Drawings

This invention will be further explained and exemplified with reference to the drawings showing embodiments and by way of illustration only. In the drawings:

Fig. Ia shows a perspective view of one laminate component part, Fig. Ib shows a perspective view of another component part,

Fig. 2a shows a perspective view of an alternative laminate component part,

Fig. 2b shows a perspective view of another alternative component part, and

Fig. 3 illustrates a step in the method of manufacture of a component part.

Detailed Description of an Embodiment Referring to Figs. Ia and Ib of the drawings one construction of laminate material is shown comprising outer layers 1 and 2 of a rigid material comprising wood such as beech wood, MDF (medium density fibreboard), plywood, or plastics material having similar characteristics, being flexurally resisting and capable of defining a constructional shape. Each outer layer 1 and 2 is bonded to a respective surface of an inner compressibly resilient material comprising a rubber or closed cell foam material 3. In this example, the outer layers 1 and 2 comprise MDF and the inner layer 3 is a closed cell foam material manufactured by Zotefoam pic, of Croydon, Surrey, UK and known under the name "standard LD33". A less resilient material to be used comprises "standard LD45". It will be understood that the drawings show only a part of a constructional component and in detail to illustrate the layer construction.

In a typical construction the thickness of the material 1 is of the order of between 4 mm and 15 mm and the foam 3 is of the order of 4 mm to 15 mm. In the laminate material of Fig. Ia materials 1 and 2 are 5 mm thick and the foam 12mm thick

The component part B shown in Fig. Ib includes a recess, or a slot, 4. For a toy component, for example a child's construction toy, the dimension W of the recess 4 is made, or cut, to be slightly less, say lmm to 3mm, than the dimension X of the component Ia. Such dimensions being in an unstressed condition of the components with the material 3 uncompressed. By this means the component part A of Fig. Ia may be compressed across the dimension X and located within the recess 4 of the component B; release of the compressive force then permitting the dimension X of the component A to restore and thus be held within the width W of the recess 4. The material of this invention may thus be used as a basis for the manufacture of parts for a constructional kit or a child's toy which may be easily put together by the engagement of one preshaped piece as A into a second preshaped piece, as B, and so on to build-up a complete article from a plurality of such engaging pieces. It will be understood that the pieces are retained together through the restoring force of the closed cell foam material forming the centre of the "sandwich" construction.

This invention thus provides also a child's constructional toy or a kit of parts for constructing a toy or model comprising a set of components such as A and B formed from a laminate material with at least three layers, each of the outermost layers 1 and 2 being of a flexurally resistant material such as wood and each bonded to a respective surface of an inner layer 2 being of a compressibly resilient material such as a closed cell foam material, the components being made to interengage using a slotted or recessed arrangement 4 in one component B whereby the other component A can be fitted edgewise into the slot 4 by a slight compression applied between the outer layers of the component A. The slot width W of the component B is marginally narrower than the uncompressed width X of the component A whereby after such engagement the restoration of the width X of the provides retention

Figs. 2a and 2b show a modification and as will be apparent in this example the sandwich laminate is formed from five layers being the outer layers 1 and 2 but with a central layer 5 of a similar material. Two layers of the foam material 6 and 7 are used. More layers can be provided as required, for example the laminate may comprise the three layers of Figs 1, the five layers of Figs 2, or seven or nine layers. In this embodiment the material 1, 2 and 5 is 5 mm thick the foam being 4 mm thick.

It will be appreciated that the main object of the laminate material of this invention is to provide outer layers giving a stable overall shape for a component made therefrom but nevertheless permitting components to be engaged and retained together to enable disassembly when required.

The laminate material provided by this invention is not limited to use as constructional components or parts for toys.

This invention also relates to a method of manufacturing a laminate material primarily, but not essentially, for a constructional component the material having at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to a respective surface of an inner layer being of a compressibly resilient material, the method comprising; coating one surface of each outer layer or both surfaces of an inner layer, or all such surfaces, with an adhesive; bringing said surfaces into face to face contact; applying pressure across the outer layers; maintaining the pressure for a time to achieve an adhesive bond between the surfaces; removing the pressure.

The outer layers may be grooved on the surfaces bonded to the inner layer to assist adhesion.

In the case where more than three layers are provided then the relevant mating surfaces are coated with adhesive to form the multi-layered laminate structure.

In a preferred embodiment of the method and as shown in Fig. 3 adjacent edge portions of the outer layers 1 and 2 and middle layer 5 are provided with a rigid filler pieces or spacers 8 and 9 the overall width of which is arranged such that pressure applied to the outer layers compresses the foam material 6 and 7 only to a limit. The filler pieces thus forming a stop. This arrangement ensures that when the compressive force is applied the outer layers remain parallel and the displacement is limited during the adhesive bonding step of the method. The filler pieces can be removed or discarded, for example when the laminate is cut-up to form components.

When wood is used for the outer layers 1 and 2 a further step in the method comprises "wetting" the outermost surface of each layer using a spray of water or other media specifically to produce outward bowing of the material. In another embodiment a lacquer or varnish is applied This step has been found to counteract an opposite inward bowing of the wood component which can occur an application of the adhesive.

The adhesive used is preferable a contact type such as "EVO-STIK" multi-purpose impact ( a registered trade mark).

In summary, a child's constructional toy or a kit of parts for constructing a toy or model comprises a set of components formed from a laminate material with at least three layers, each of the outermost layers being of a fiexurally resistant material such as wood and each bonded to a respective surface of an inner layer being of a compressibly resilient material such as a closed cell foam material, the components being made to interengage using a slotted or recessed arrangement in one component whereby the other component can be fitted edge-wise into the slot by a slight compression applied between the outer layers of the component. The slot width of the one component is marginally narrower than the uncompressed width of the other component whereby after such engagement the restoration of the width provides retention.

Claims

1. A constructional component part for use in combination with other component parts, said component part being capable of interengagement with another component part, the component part being formed from at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to an inner layer being of a compressibly resilient material.

2. A set of constructional component parts each said part being in accordance with claim 1.

3. A set of constructional component parts in accordance with claim 2, wherein one part at least includes a slot or recess disposed transversely to an edge of the laminate, the width of the slot or recess being less than the uncompressed thickness of another component part, such that the other part may be located in the slot of the one part by compressive force applied across the outer layers of said part reducing the thickness through compression of the resilient material, removal of the compressive force allowing restoration of the compressive material to retain the other part within the recess of the one part.

4. A component or set of components in accordance with any preceding claim, wherein the outermost layers comprise a stiff or rigid material such as wood, wood substitute or a plastics material, said material forming the basic structural shape of the component

5. A component or set of components in accordance with any preceding claim, wherein the inner layer or layers comprise a foam material or a rubber material.

6. A component or set of components in accordance with claim 5, wherein the foam material is a closed cell foam material or a foamed rubber material.

7. A component or set of components in accordance with any preceding claim, wherein the layers forming the laminate are bonded together at their mating surfaces using an adhesive agent applied over the whole of such mating surfaces.

8. A child's constructional toy or a kit of parts for constructing a toy or model comprising a set of components in accordance with any preceding claim, the components being made to interengage using a slotted or recessed arrangement in one part whereby one part can be fitted edge-wise into the slot of another part by a slight compression applied between the outer layers of the one part, the slot of the other part being marginally narrower than the uncompressed width of the one part whereby after such engagement the restoration of the width of the one part provides retention.

9. A component or set of components in accordance with any preceding claim, wherein more than three layers are provided forming the laminate including one or more inner layers of flexurally resistant material bonded at each of its sides to a compressibly resilient material which, in turn, are bonded to the outer layers or further inner layers.

10. A laminate material having at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to a respective surface of an inner layer being of a compressibly resilient material.

11. A laminate constructional component having at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to a respective surface of an inner layer being of a compressibly resilient material.

12. A laminate material or constructional component in accordance with claim 10 or 11, comprising alternate laminated layers of the flexurally resistant material each bonded to a respective surface off the compressibly resilient material, wherein the outermost layers of the laminate each comprise the flexurally resistant material.

13. A method of manufacturing a laminate material primarily, but not essentially, for a constructional component the material having at least three layers, each of the outermost layers being of a flexurally resistant material and each bonded to a respective surface of an inner layer being of a compressibly resilient material, the method comprising; coating one surface of each outer layer or both surfaces of an inner layer, or all such surfaces, with an adhesive; bringing said surfaces into face to face contact; applying pressure across the outer layers; maintaining the pressure for a time to achieve an adhesive bond between the surfaces; removing the pressure.

14. A method in accordance with claim 12, wherein more than three layers are provided, the relevant mating surfaces of the layers being each coated with adhesive to form a multi-layered laminate structure.

15. A method in accordance with claim 12 or 13, wherein adjacent edge portions of the outer layers and any further flexurally resistant material intermediate layer are provided with a rigid filler pieces or spacers the overall width of which is arranged such that pressure applied to the outer layers compresses the foam material only to a defined limit.

16. A method in accordance with claims 12, 13 or 14 including the further step of wetting the outermost surface of each flexurally resistant material layer using water or other media to produce an outward bowing of the material.

17. A method in accordance with any preceding claim 12 to 15, wherein a lacquer or varnish is applied to the outermost surface of each flexurally resistant material layer.

18. A constructional component having at least three layers, each of the outermost layers being of a more rigid and less compressible material than an inner layer, each outer layer being bonded to a respective surface of the inner layer.

19. A constructional component or a method of making same in accordance with any preceding claim, wherein the or each inner layer may be a sheet of material alternatively the inner layer may comprise discrete areas of material each spaced from one another.

20. A constructional component comprising a laminate as described herein and exemplified with reference to Figs 1 or Figs 2 or Fig. 3 of the drawings.

21. A child's toy formed from a plurality of component parts at least some such parts being formed from a laminate material as described herein and exemplified.