WO2019083499A1

WO2019083499A1 - System of interlocking building blocks

Info

Publication number: WO2019083499A1
Application number: PCT/US2017/057965
Authority: WO
Inventors: William C. Macarthur
Original assignee: Octablox, LLC
Priority date: 2017-10-24
Filing date: 2017-10-24
Publication date: 2019-05-02
Also published as: DK202070188A1; US20200282323A1; DK180702B1

Abstract

An improved system of interlocking building blocks is provided. The system of interlocking building blocks includes a top block component and a bottom block component that are removably attached to each other to form a modular block with a hollow interior. The hollow interior can interchangeably receive a number of components, for example motors, electronics, and batteries. The exterior of the modular block includes a system of octagonal openings that are shaped to receive an octagonal connector for coupling adjacent modular blocks, or for receipt of flange bearing for an axle for example. Collectively, interlocking blocks can be joined together to build and create a generally limitless number of robust and modular structures and devices.

Description

SYSTEM OF INTERLOCKING BUILDING BLOCKS

FIELD OF THE INVENTION

[0001] The present invention relates generally to building blocks, and more particularly to a system of building blocks that are assembled with additional snap-fit connectors.

BACKGROUND OF THE INVENTION

[0002] Interconnectable building blocks are widely known. For example, toy building blocks include a variety of small blocks that are interconnectable with each other to form a larger construction. Some blocks include additional features, including for example a DC motor or an LED light. These building blocks can be used in combination with each other to form a powered construction, for example a small robot, a motorized toy train, or a remote controlled car.

[0003] Despite their widespread popularity, many existing building blocks systems are intended for use exclusively as a children's toy, and are poorly suited for use outdoors or for larger constructions. Accordingly, there remains a continued need for an improved system of interlocking building blocks. In particular, there remains a continued need for an improved system of building blocks that can appeal to hobbyists of all ages, while also allowing for the assembly and operation of motorized vehicles for recreational use by children and adults. In addition, an age-appropriate collection of building blocks is described and includes large soft blocks for the construction of small enclosures. Moreover, a collection of smaller blocks is described that, in one embodiment, can be used for modeling and animatronic constructions.

SUMMARY OF THE INVENTION

[0004] An improved system of interlocking building blocks is provided. The system of interlocking building blocks includes a top block component and a bottom block component that are removably attached to each other to form a modular block with a hollow interior. The hollow interior can interchangeably receive a number of components, for example motors, electronics, and batteries. The exterior of the modular block includes a system of octagonal openings that are shaped to receive an octagonal tube for coupling adjacent modular blocks, or for receipt of a flange bearing or other type of bearing. Collectively, the system of interlocking blocks can be used to create a variety of robust constructions, including electrically powered scooters and go- carts, construction equipment or larger machines.

[0005] In one embodiment, the top block component includes a top wall, a bottom edge, and a first plurality of sidewalls that extend orthogonally from the top wall to the bottom edge. The bottom block component includes a bottom wall, a top edge, and a second plurality of sidewalls that extend orthogonally from the bottom wall to the top edge. The sidewalls have an interior surface and an opposing exterior surface. The top wall of the top block component and the bottom wall of the bottom block component each include a complementary array of vertically (orthogonally) disposed octagonal sockets and a complementary array of vertically (orthogonally) disposed hexagonal sockets. The vertically disposed octagonal sockets are disposed in multiple rows, with the octagonal sockets of each row being offset set with respect to the octagonal sockets of the adjacent rows. Similarly, the vertically disposed hexagonal sockets are disposed in multiple rows, with the hexagonal sockets of each row being offset set with respect to the hexagonal sockets of the adjacent rows. Each octagonal socket includes an octagonal hole with a flat bottom ledge, opening to a smaller-diameter octagonal hole. Each hexagonal socket includes a hexagonal hole with a flat bottom ledge, opening to a smaller- diameter cylindrical hole. In this respect, the octagonal sockets and the hexagonal sockets include a counterbore construction. The first and second sidewalls contact each other along an interface between the bottom edge of the top block component and the top edge of the bottom block component, and define horizontally disposed octagonal sockets and horizontally disposed hexagonal sockets.

[0006] In another embodiment, the octagonal tube is a snap fit connector that is shaped to interchangeably fit within the vertically disposed octagonal sockets and the horizontally disposed octagonal sockets. The octagonal tube is received within the octagonal socket of a first block and a second block to removably couple the first and second blocks together. The system also includes an octagonal rod that is shaped to interchangeably fit within each of the vertically disposed octagonal sockets and the horizontally disposed octagonal sockets, the rod being longer than the octagonal tube.

[0007] In another embodiment, a modular block includes two portions that are angled with respect to each other. This block includes an outer wall having a convex portion and a first plurality of sidewalls extending orthogonally from the outer wall. A second block component includes an outer wall having a corner portion and a second plurality of sidewalls extending orthogonally from the outer wall. The outer wall of the first block component and the outer wall of the second block component define a complementary array of octagonal sockets and a complementary array of hexagonal sockets, such that at least two of the octagonal sockets are orthogonal to each other and at least two of the hexagonal sockets are orthogonal to each other. The first and second sidewalls abut one another along an interface to define a v-shaped cross- section along the length of the interlocking block.

[0008] As discussed herein, the system of interlocking building blocks is suitable for hobbyists of all ages and can be used in the assembly of robust constructions, including scooters and go-carts. The interlocking blocks can be scaled down in size to enable the construction of smaller devices such as robots or other machines. The interlocking building blocks can alternatively include a system of monolithic blocks, scaled up in size, if desired, formed of foam for use by children in the creation of forts, castles, igloos and other constructions. The monolithic blocks can include the same arrangement of octagonal openings and octagonal tubes to couple adjoining blocks together, free of any tools. Accordingly, the system of interlocking building blocks provides added versatility, robustness, and appeal over many existing toy building blocks that are currently commercially available.

[0009] These and other features and advantages of the present invention will become apparent from the following description of the invention, when viewed in accordance with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a perspective view of a system of interlocking blocks in accordance with an embodiment of the present invention;

[0011] Figure 2 is a perspective view of a block constituting a portion of the system of

Figure 1;

[0012] Figure 3 is an exploded view of the block of Figure 2, illustrating a top block component and a bottom block component;

[0013] Figure 4 is a top view of the top block component of Figure 3;

[0014] Figure 5 is a top view of the bottom block component of Figure 3;

[0015] Figure 6 is a longitudinal side view of the top block component of Figure 3;

[0016] Figure 7 is a lateral side view of the top block component of Figure 3;

[0017] Figure 8 is a cross-sectional view of the top block component taken along line

VIII- VIII of Figure 4;

[0018] Figure 9 is a perspective view of an octagonal tube of the system of interlocking blocks;

[0019] Figure 10 is a perspective view of an octagonal rod of the system of interlocking blocks;

[0020] Figure 11 is a bottom perspective view of a corner block or right angle block of the system of interlocking blocks;

[0021] Figure 12 is a top perspective view of the corner block or right angle block of

Figure 11 ; [0022] Figure 13 is an exploded view of the corner block or right angle block of Figure

11, illustrating top block components and bottom block components;

[0023] Figure 14 is a bottom perspective view of the corner block or right angle block component, showing nuts contained within recesses designed into the structure;

[0024] Figure 15 is a side view of the corner block or right angle block of Figure 11 ;

[0025] Figure 16 is a bottom perspective view of an elbow block or 45 degree block of the system of interlocking blocks;

[0026] Figure 17 is a top perspective view of the elbow block or 45 degree block of

Figure 16;

[0027] Figure 18 is an exploded view of the elbow block or 45 degree block, illustrating top block components and bottom block components;

[0028] Figure 19 is a bottom perspective view of the elbow block or 45 degree block component showing nuts contained within recesses designed into the structure;

[0029] Figure 20 is a side view of the elbow block or 45 degree block of Figure 16;

[0030] Figure 21 is a perspective view of another example of a block of the system of interlocking blocks;

[0031] Figure 22 is an exploded view of the block of Figure 21, showing nuts contained by recesses designed into the structure;

[0032] Figure 23 is an exploded view of the system of interlocking blocks, illustrating an assembly of several blocks and connecting octagonal tubes and rods;

[0033] Figure 24 is an exploded view of the system of interlocking blocks, illustrating an assembly of several blocks, including a corner block or right angle block and an elbow block or 45 degree block, and connecting octagonal tubes and rods;

[0034] Figure 25 is an exploded view of a block of the system of interlocking blocks, including an alternate rod; [0035] Figure 26 is the block and alternate rod of Figure 25, illustrating inserting bolts to secure the alternate rod within the block;

[0036] Figure 27 is a top perspective view of the bottom block component including nuts installed therewithin;

[0037] Figure 28 is an exploded view of adjacent blocks connected by a long bolt;

[0038] Figure 29 is a view of the connected blocks of Figure 28;

[0039] Figure 30 is an exploded view of a block of the system of interlocking blocks, including multiple alignment pegs;

[0040] Figure 31 is a perspective view of different sized top blocks mated with different size bottom blocks;

[0041] Figure 32 is a perspective view of two u-joint blocks and a cross of the system of interlocking blocks;

[0042] Figure 33 is a perspective view of the two u-joint blocks joined by the cross of

Figure 32;

[0043] Figure 34 is a partially exploded view of the two u-joint blocks joined by the cross of Figure 32;

[0044] Figure 35 is a perspective view of the cross of Figure 32;

[0045] Figure 36 is a perspective view of a foam block in accordance with another embodiment; and

[0046] Figure 37 is a top plan view of the foam block of Figure 36.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

[0047] The invention as contemplated and disclosed herein includes a system of interlocking building blocks. The system includes multiple blocks having polygonal openings, for example octagonal and hexagonal openings, and includes snap-fit connectors used to join adjacent ones of the multiple blocks together. The blocks and connectors are the basic members of the system and can be joined together to build and create a generally limitless number of robust and modular structures and devices. A description of the interlocking blocks and connectors is set forth in Part I below, and a description of their use follows in Part II below. I. Interlocking Blocks and Connectors

[0048] Referring to Figures 1-10, an interlocking block system in accordance with one embodiment is illustrated and generally designated 10. As discussed below, the interlocking block system 10 includes one or more blocks 12 and one or more connectors in the form of tubes 100 (shown in Figure 9) and rods 110 (shown in Figure 10). The block 12 is generally in the form of a rectangular cuboid, i.e., an object with six rectangular faces at right angles to each other; however, the block may be in the form of another three dimensional shape. In this embodiment, the block 12 is a cuboid having six rectangular faces at right angles to each other, being 6" x 4" x 2", while in other embodiments the cuboid has different dimensions, for example 6' x 4' x 2'. As discussed below, the block 12 can be made up of two portions, namely a top block component 20 and a bottom block component 40, to define a cavity therebetween. The top and bottom block components 20 and 40 may be substantially identical and/or mirror-image of one another, but need not be.

[0049] Further, the block 12 can be formed instead as a single component, for example a monolithic closed cell foam block or a monolithic open cell foam block. In this embodiment, the monolithic foam block 12 is a cuboid having six rectangular faces at right angles to each other, being 18" x 12" x 6", while in other embodiments the cuboid can have different dimensions, for example 18' x 12' x 6'. Each rectangular face includes one or more octagonal sockets and one or more hexagonal sockets. Each octagonal socket includes an octagonal hole with a flat bottom ledge, opening to a smaller-diameter octagonal hole. Each hexagonal socket includes a hexagonal hole with a flat bottom ledge, opening to a smaller-diameter cylindrical hole. In this respect, the octagonal sockets and the hexagonal sockets include a counterbore. The octagonal sockets on opposing surfaces of the cuboid block 12 are aligned with each other, and the hexagonal sockets on opposing surfaces of the cuboid block 12 are aligned with each other. As used herein, sockets that are "aligned" with each other are coaxial, that is, defining a common longitudinal axis.

[0050] Referring to Figures 2 through 8, the top block component 20 includes a top wall

22, four sidewalls 24, 26, 28, 30, and a bottom edge 32. The sidewalls 24, 26, 28, 30 extend orthogonally from the top wall 22 and terminate in the bottom edge 32. The top wall 22 and each of the sidewalls 24, 26, 28, 30 have an interior surface and an opposing exterior surface. Additionally, the bottom edge 32 of the top block component 20 includes one or more projections 34, shown in Figures 6-8, and one or more recesses 36, shown in Figure 3. The projections 34 extend down beyond the bottom edge 32, and the recesses 36 extend up into the top block component 20. The projections 34 and recesses 36 are spaced about the bottom edge 32 of the top block component 20.

[0051 ] The bottom block component 40 is substantially similar and complimentary to the top block component 20 and includes a bottom wall 42, four sidewalls 44, 46, 48, 50, and a top edge 52. In one embodiment the bottom block component 40 and the top block component 20 are identical, but face each other and are rotated 180 degrees about their largest face with respect to the other block component. The sidewalls 44, 46, 48, 50, extend orthogonally from the bottom wall 42 and terminate in the top edge 52. The bottom wall 42 and each of the sidewalls 44, 46, 48, 50, have an interior surface and an opposing exterior surface. Additionally, the top edge 52 of the bottom block component 40 includes one or more projections 54 and one or more recesses 56. The projections 54 extend up beyond the top edge 52, and the recesses 56 extend down into the bottom block component 40. The projections 54 and recesses 56 are spaced about the top edge 52 of the bottom block component 40 as shown in Figure 3.

[0052] Multiple vertical octagonal sockets 60a and vertical hexagonal sockets 80a extend down from the top wall 22 of the top block component 20; and multiple vertical octagonal sockets 60b and vertical hexagonal sockets 80b extend up from the bottom wall 42 of the bottom block component 40. Further, the vertical octagonal sockets 60a are aligned with the vertical octagonal sockets 60b and the vertical hexagonal sockets 80a are aligned with the vertical hexagonal sockets 80b. Together, the octagonal sockets 60a and 60b define a complementary and interconnecting array of vertically disposed octagonal sockets 60. Likewise, the hexagonal sockets 80a and 80b define a complementary and interconnecting array of vertically disposed hexagonal sockets 80. Each octagonal socket includes an octagonal hole with a flat bottom ledge, opening to a smaller-diameter octagonal hole. Each hexagonal socket includes a hexagonal hole with a flat bottom ledge, opening to a smaller-diameter cylindrical hole. In this respect, the octagonal sockets and the hexagonal sockets include a counterbore.

[0053] The four sidewalls 24, 26, 28, 30 of the top block component 20 and the four sidewalls 44, 46, 48, 50 of the bottom block component 40 contact each other along an interface 58 between the bottom edge 32 of the top block component 20 and the top edge 52 of the bottom block component 40. Portions of multiple horizontally disposed octagonal sockets 70a and 70b are formed adjacent each of the bottom and top ends 32, 52 of the top and bottom block components 20, 40. Together, the octagonal sockets 70a and 70b define multiple horizontally disposed octagonal sockets 70, best shown in Figure 2. The horizontal octagonal sockets 70 extend between pairs of opposed sidewalls. Likewise, portions of one or more horizontally disposed hexagonal sockets 90a and 90b are formed adjacent each of the bottom and top edges 32, 52 of the top and bottom block components 20, 40. Together, the horizontal hexagonal sockets 90a and 90b define a horizontally disposed hexagonal socket 90.

[0054] The vertical and horizontal octagonal sockets 60, 70 each include a stepped area that decreases at an octagonal ledge or shoulder 62 and 72, respectively. The vertical and horizontal hexagonal sockets 80, 90 include a stepped area that decreases at a circular ledge or shoulder 82, 92. The octagonal sockets 60, 70 define a cross-sectional area, the hexagonal sockets 80, 90 define a cross-sectional area, and the cross-sectional area of the octagonal sockets 60, 70 is greater than the cross-sectional area of the hexagonal sockets 80, 90. Stated differently, the octagonal sockets 60, 70 are generally larger than the hexagonal sockets 80, 90. Further, the vertical octagonal sockets 60 include a ledge depth 64 (see Figures 6 and 8) that is defined as the distance between the top wall 22 or the bottom wall 42, and the respective octagonal shoulder 62, being equal to the height of sidewalls 62 in Figure 8. Likewise, the horizontal octagonal sockets 70 include a ledge depth 74 (see Figure 5) that is defined as the distance between the side walls 22-30, 44-50 and the respective octagonal shoulder 72.

[0055] The system of interlocking blocks 10 includes an octagonal snap-fit connector, separate from the blocks, and that joins any adjacent two blocks together by non-adhesive interference fit or friction fit. Referring to Figure 9, the octagonal snap-fit connector can include an octagonal tube 100. The octagonal tube 100 is a hollow, octagonal-shaped tube that is sized and shaped to interchangeably fit within each or any of the vertically disposed octagonal sockets 60 and the horizontally disposed octagonal sockets 70. The octagonal tube 100 has an exterior surface 100a and an interior surface 100b. Each of the eight faces or sides of the exterior surface 100a includes a raised rib 102 extending in the longitudinal direction of the octagonal tube 100. In addition, the octagonal tube 100 is sized to have a length that is slightly less than twice the ledge depth 64, 74. As will be discussed further below, the octagonal tube 100 and rib 102 are sized to fit snugly into the octagonal sockets 60, 70.

[0056] Referring to Figure 10, the interlocking block system 10 includes one or more connecting octagonal rods 110. The octagonal rod 110 is an elongated, hollow or solid, octagonal-shaped rod that is sized and shaped to interchangeably fit within each or any of the vertically disposed octagonal sockets 60 and the horizontally disposed octagonal sockets 70. The rod 110 has an exterior surface 110a and an interior surface 110b. The rod 110 can be provided in lengths ranging from at least the depth, width, and/or length of the block 12 to at least twice the depth, width, and/or length of the block 12. The length of the rod 110 is provided such that external accessories or components can be attached to the block 12 via the rod 110. Further, the length of the rod 110 can be provided such that two adjacent blocks 12 can be connected, where the rod 110 extends through both blocks 12.

[0057] As further shown in Figure 3, each corner of the bottom block component 40 includes either of a projection 54 or a recess 56. In corresponding fashion, each corner of the top block component 20 includes either of a recess 36 or a projection 34. The top block component 20 further includes one or more towers 116a and the bottom block component 40 further includes one or more towers 116b. Tower 116a extend down from the top block component 20 and tower 116b extends up from the bottom block component 40. Each tower includes two projections 34, 54 and two recesses 36, 56, such that tower 116a releasably engages tower 116b by interference fit or friction fit. Referring back to Figures 3, 5 and 8, a central tower 116b (Figures 3, 5) extends up from the bottom wall 42 of the bottom block component 40; and a central tower 116a (Figure 8) extends down from the top wall 22 of the top block component 20. The central towers 116a, 116b have a respective bottom edge 118a (Figure 8) and top edge 118b (Figures 3, 5) that contact along the interface 58. The towers 116a, 116b include projections 34, 54 that extend from the edge 118a, 118b of the towers 116a, 116b, and recesses 36, 56 that extend into the towers 116a, 116b. The towers 116a, 116b include a nut- shaped recess 120 disposed adjacent the bottom and top edges 118a, 118b. The nut-shaped recess 120 is configured to receive a standard sized hex nut 122, for example a 1/4" thread diameter hex nut (7/16" across the flats) as shown in Figure 2, 25, and best shown in Figure 27. The nut-shaped recess 120 can be sized and shaped, for example a hexagon, to hold the nut 122 and prevent it from turning when a bolt is threaded into the nut 122.

[0058] When the top block component 20 and the bottom block component 40 are assembled or mated together, the block components 20, 40 contact each other along the interface 58 between the bottom edge 32 of the top block component 20 and the top edge 52 of the bottom block component 40. The projections 34 of the top block component 20 are received within recesses 56 of the bottom block component 40 and vice versa. The projections 34, 54 and recesses 36, 56 can have a snap fit interface. Optionally, the block components 20, 40 can include and adhesive along the interface 58 to secure the components together. Further optionally or alternatively, the block components 20, 40 can be ultrasonically welded together.

[0059] The block components 20 and 40 can also be secured together with a conventional nut 122 and bolt 124. The nut 122 is placed into one of the vertical hexagonal sockets 80, and the bolt 124 extends through the block 12 and is threaded into the nut 122. The nut 122 and bolt 124 are tightened against the circular shoulders 82 of the hexagonal socket 80. Multiple nuts 122 and bolts 124 can be used to secure the block components 20, 40 together. The nut 122 and nut-shaped recess 120 of the tower 116a, 116b are co-axially aligned with the horizontal hexagonal socket 90. With the top and bottom block components 20, 40 mated, the nut-shaped recess 120 is formed in part by each of the top block component 20 and the bottom block component 40. Accordingly, a bolt (not shown) can extend through the sidewalls of the block components 20, 40 and be threaded into the nut 122 to secure an accessory or component to the block 12, as described further below. The bolt 124 can include a circular head with a recessed drive, for example a hex drive, a torx drive, or other drive. The head of the bolt tightens against the circular shoulder 92 of the horizontal hexagonal socket 90.

[0060] The top wall 22 of the top block component 20 and the bottom wall 42 of the bottom block component 40 are spaced apart and define a cavity 98 within the block 12. Components useful to the block system 10 can be provided within the cavity 98; for example, a battery, motor, a pump, etc. The block 12 can be disassembled to gain access into the cavity 98 to replace components housed within the cavity 98, etc. [0061] According to a second embodiment, the interlocking block system 10 includes a corner block or right angle block 212, as illustrated in Figures 11-15. The corner block 212 is structurally and functionally similar to the block 12 of Figures 1-8, with like numbers corresponding to like features (e.g., socket 60 from Figures 1-8 is renumbered socket 260 in Figures 11-15), except that the walls 222, 224, 226, 228, 230, 242, 244, 246, 248 are arranged to define a v-shaped cross-section along the length of the corner block 212. That is to say, the walls 222, 224, 226, 228 230, 242, 244, 246, 248 include a substantially right angle. The top outer wall 222 of the first block component 220 has a convex portion 230, and the bottom outer wall 242 of the second block component 240 has a corner portion 232. The octagonal sockets 260 are orthogonal to one another, and the hexagonal sockets 280 are orthogonal to one another. Optionally, the top outer wall 222 can be formed by two mitered walls 222a and 222b and the bottom outer wall 242 can be formed by two mitered walls 242a and 242b.

[0062] According to a third embodiment, the interlocking block system 10 includes an elbow block or 45 degree block 312, as illustrated in Figures 16-20. The elbow block 312 is structurally and functionally similar to the block 12 of Figures 1-8, with like numbers corresponding to like features (e.g., socket 60 from Figures 1-8 is renumbered socket 360 in Figures 16-19), except that the sidewalls 322, 324, 326, 328 330, 342, 344, 346, 348 include an angle. The top outer wall 322 of the first block component 320 has a convex portion 330, and the bottom outer wall 342 of the second block component 340 has an angled portion 332. The octagonal sockets 360 are arranged at an angle to one another, and the hexagonal sockets 380 are arranged at an angle to one another. Optionally, the top outer wall 322 can be formed by two mitered walls 322a and 322b and the bottom outer wall 342 can be formed by two mitered walls 342a and 342b.

[0063] It should be understood that any of the above described blocks could be provided in greater or lesser lengths and/or widths. For example, the block 12 illustrated in Figure 2 is said to be a 2x3 block, meaning it has two lateral or outside rows of sockets 60, each row including three sockets 60. Another example shown in Figures 21 and 22, the block can be a 1x2 block. The block 412 of Figures 21 and 22 in accordance with a fourth embodiment is structurally and functionally similar to the block 12 of Figures 1-8, with like numbers corresponding to like features (e.g., socket 60 from Figures 1-8 is renumbered socket 460 in Figures 21-22), except that the block 412 of Figures 21 and 22 is a 1x2 block. Other examples include a 1x3 block, a 3x3 block, a 2x4 block, etc. Further, the corner and elbow blocks 212, 312 could be provided in greater or lesser lengths and/or widths as well, and at angles other than 90 and 45 degrees.

[0064] According to yet another embodiment, the interlocking block system 10 includes an alternate rod 710, as illustrated in Figures 25-26. The rod 710 is structurally and functionally similar to the rod 110 of Figures 1-8, with like numbers corresponding to like features (e.g., rod 110 from Figures 1-8 is renumbered rod 710 in Figures 25-26), except that the rod 710 includes multiple through holes 712. The holes 712 are aligned on opposite sides of the rod 710 such that bolt(s) 124 can pass through the rod 710. The bolt 124 is inserted into the horizontal hexagonal socket 690, extending through the aligned through holes 712 of the rod 710, and is threaded into a nut 122 installed in the nut-shaped recess 720 in the central tower 716a, 716b. This arrangement secures the rod 710 within the block 612 such that external accessories or components can be attached to the block 612 via the rod 710. Similarly, a bolt 124 can extend through the vertical hexagonal socket 680 and aligned holes 712 of the rod 710 to secure the block components 620 and 640 together, even with a rod 710 installed through the block 612.

[0065] According to another embodiment, the interlocking block system 10 includes a long bolt 924, as illustrated in Figures 28 and29, with like numbers corresponding to like features (e.g., bolt 124 is renumbered bolt 924 in Figures 27-29). The long bolt 924 is long enough to pass through the hexagonal socket 890 of the block 812 and into an adjacent block 812' to engage the nut 122 seated in the recess 920 within that block 812'. Utilizing the long bolt 724 provides another means of affixing adjacent blocks together.

[0066] According to yet another embodiment, the interlocking block system 10 includes a peg 926, as illustrated in Figure 30, with like numbers corresponding to like features. The peg 926 is illustrated as substantially barrel-shaped with tapered half-portions; however, other suitable shapes are also contemplated. For example, the peg 926 can include an eight-side exterior and a cylindrical interior through-hole. The eight-side exterior can taper from its middle to its end portions along the longitudinal direction of the peg 926. The peg 926 is sized and shaped to be inserted into the block component 820, 840 corner recesses 836, 856 and tower recesses and are used instead of (or in addition to) the projections 834, 854 of the embodiments described above. For example, the bottom block component 840 can include only corner recesses and tower recesses, and the top block component 820 can include only corner recesses and tower recesses, such that pegs 926 are used to secure the bottom block component 840 to the top block component 820 by interference fit of friction fit without the use of projections 834, 854. The pegs 926 align the two block components 820, 840 as they are joined together. The pegs 926 also allow two block components to be offset from one another and form larger blocks from multiple different-sized block components. For example, Figure 31 shows a new 2 x 4 block that can be created by securing a 2 x 3 top block component 820 to a 2 x 3 bottom block component 840, having offset them from one another by one octagonal unit. The "overhangs" are then completed by securing a 1 x 2 top block component 820' and a 1 x 2 bottom block component 840' thus completing the new 2 x 4 block.

[0067] According to another embodiment, the interlocking block system 10 includes a u- joint block 1012, as illustrated in Figures 32-35. The u-joint block 1012 is structurally and functionally similar to the block 12 of Figures 1-8, with like numbers corresponding to like features (e.g., top block component 20 from Figures 1-8 is renumbered top block component 1020 in Figures 32-35), except that the sidewall includes a u-shaped yoke 1104 extending therefrom. The yoke 1104 includes spaced yoke arms 1105 that include holes 1106 at the distal ends of the yoke arms 1105, and a yoke hub 1107 that extends between the yoke arms 1105.

[0068] Two u-joint blocks 1012 can be joined together with a spider, journal, or cross

1108, as commonly referred to by those skilled in the art. In the example illustrated in Figure 35, the cross 1108 is an octagonal member that includes four trunnions 1109 extending therefrom. The trunnions 1109 are received within the holes 1106, 1106' in the yoke arms 1105, 1105' of the u-joint blocks 1012, 1012'. The cross 1108 is installed in blocks 1012, 1012' before the top block components 1020, 1020' and the bottom block components 1040, 1040' are assembled or mated together such that the trunnions 1109 are captured within the yoke arm holes 1106, 1106'. This arrangement provides a pivotable coupling of two u-joint blocks 1012, 1012'; the blocks 1012, 1012' are oriented orthogonal to one another, and are able to pivot independent of one another about the trunnions 1109 of the cross 1108 to which they are each joined.

[0069] A foam block in accordance with a further embodiment is depicted in Figures 36-

37 and generally designated 1212. In this embodiment, the foam block 1212 is a unitary element formed of closed cell foam or open cell foam. The foam block 1212 is a cuboid having an outer surface 1214 defining six rectangular faces at right angles to each other. Each rectangular face includes one or more polygonal openings 1216. As shown in Figure 37, upper and lower rectangular faces include eight octagonal openings 1216 extending entirely through the foam block 1212 as through-holes. The eight octagonal openings are disposed in three rows, with the octagons of each row being offset set with respect to the octagons of the adjacent rows. The side rectangular faces also include two or three octagonal openings 1216 extending entirely through the foam block 1212 as through-holes. The octagonal openings on opposing side surfaces of the foam block 1212 are aligned with each other, such that opposing surfaces are mirror images of each other. The octagonal through-holes are die-cut in the current embodiment, while in other embodiments the octagonal through-holes are co-molded with the foam block 1212. The blocks described above can also be formed from foam in like manner, including blocks 12, 212, 312, 412, 1012 for example. The blocks need not be cuboids as shown in Figures 36 and 37, but may be polyhedrons of any kind to allow the construction of various non-orthogonal structures.

II. System of Interlocking Blocks and Connectors

[0070] The interlocking block system 10 can include multiple blocks 12, 212, 312, 412,

612, 812, 1012, 1212 and connectors 100, 110, 710 used to join adjacent blocks together. The blocks 12, 212, 312, 412, 612, 812, 1012, 1212 and connectors 100, 110, 710 can be joined together to build and create a generally limitless number of robust and modular structures and devices. Further, the interlocking block system 10 can be used with a variety of add-on components or accessories. These components and accessories can be mounted to or within any of blocks 12, 212, 312, 412, 612, 812 or 1012 to provide structure and/or function to the blocks. For example, a battery could be included within one of the blocks to power a motor mounted to a block. As another example, an axle could extend through coaxial flange bushings or other bearings contained within any two coaxial sockets, and wheels could be attached to the axle. Accordingly, the blocks could be utilized to create part of a motorized vehicle, for example, a scooter or a go-cart.

[0071] The blocks 12, 212, 312, 412, 612, 812, 1012 can be provided to the user in pre- assembled block form, or as unassembled blocks of individual components. In the case that the blocks 12 are not pre-assembled, the user aligns the top and bottom block components 20, 40 such that the projections 34 of the top block component 20 are received within recesses 56 of the bottom block component 40 and vice versa. Alternatively, the block components 20, 40 can include only recesses, such that pegs 926 are used to secure the bottom block component to the top block component without the use of projections 34, 54. If desired, a battery or other accessory or component can be placed within the block cavity 98 before assembling the block components 20, 40 together. The projections 34, 54 and recesses 36, 56 have a snap fit interface, providing at least temporary assembly of the block components 20, 40. To further secure the block components 20, 40 together, the user can place a nut 122 within a selected hexagonal socket 80 and thread a bolt 124, extending from the opposite side of the block 12 through the hexagonal socket 80, into the nut 122. Additional nuts and bolts can be utilized within the hexagonal sockets 80 as desired. The corner and elbow blocks 212, 312 are assembled in a similar manner. Alternatively, pegs 926 can be inserted into the corner recesses 836, 856 to align the two block components 820, 840 as they are joined together.

[0072] As illustrated in Figures 23 and 24, assembled first and second blocks 12, 12' and block 412, for example, can be joined together to create a structure. The octagonal tubes 100, octagonal rods 110, and/or rods 710 are used to removably join the first and second blocks 12, 12'. The octagonal tube 100 is inserted into one of the octagonal sockets 60, 70 of the first or second block 12, 12'. The other of the first or second block 12, 12' can be aligned as desired so that the free end of the octagonal tube 100 can be inserted into a selected octagonal socket 60, 70 of the remaining block. Multiple tubes 100 can be used to join adjacent blocks together. Further, the ribs 102 positioned around the exterior surface 100a of the tube 100 provide a snug, interference, or press fit to join adjacent blocks together. The blocks can be joined together in any viable arrangement where octagonal sockets 60, 70 can be aligned. Corner and elbow blocks 212, 312 can be joined with any of the aforementioned blocks, in a similar manner, to create the structure also. Further, any of the aforementioned blocks and connectors can be joined with the u-joint block(s) 1012 to provide a pi votable joint between adjoined blocks.

[0073] Further, octagonal rods 110 and/or rods 710 can be inserted through first and/or second blocks 12, 12' to mount accessories or other components to the assembled blocks, for example. The octagonal rods 110, 710 are sized to fit through the octagonal tube 100. So, even with a tube 100 installed, the particular socket 60, 70 can still be used to install an elongated rod 110, 710 therethrough. Additionally, a bolt 124, 724 (see Figures 3, 25, 26, and 28) can be inserted into the horizontal hexagonal socket 90, extending through the side wall of the block 12 and be threaded into the nut 122 that has been installed into the nut-shaped recess in the central tower 116a, 116b. The bolt can be utilized to secure an accessory component to the block 12. Further, the long bolt 724 is long enough to pass through the first block 12 and into an adjacent block 12' to engage the nut 122 seated within that block 12'. Utilizing the long bolt 724 provides another way for a user to affix adjacent blocks together. Of course, multiple sets of nuts and bolts can be utilized.

[0074] Referring to Figure 31, different sized block components can be assembled together in a mixed configuration, utilizing the pegs 926. In the example illustrated in Figure 31, the top block components include: a 2x3 top block component 820 and a 1x2 top block component 820'; the bottom block components include (recited in the same order as the top block components): a 1x2 bottom block component 840' and a 2x3 bottom block component 840. Together, this assembly creates a 2x4 block. Utilizing the pegs 926 in the corner recesses 836, 856 aligns the corners of the block components, and then a nut 122 and bolt 124 can be installed to secure the components together, or they can be secured with adhesive or sonically welded.

[0075] The interlocking building block system 10 described herein provides enhanced functionality and creativity for people of all ages, including children and young adults, by fostering their imagination to build and create robust and modular structures and devices using the blocks and connecting components.

[0076] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to elements in the singular, for example, using the articles "a," "an," "the," or "said," is not to be construed as limiting the element to the singular.

Claims

1. A system of interlocking blocks, wherein the interlocking blocks comprise:

a top block component including a top wall and a first plurality of sidewalls extending orthogonally from the top wall to a bottom edge; and

a bottom block component including a bottom wall and a second plurality of sidewalls extending orthogonally from the bottom wall to a top edge,

wherein the top wall of the top block component and the bottom wall of the bottom block component each include a complimentary array of vertically disposed octagonal sockets and a complimentary array of vertically disposed hexagonal sockets, and

wherein the first plurality of sidewalls and the second plurality of sidewalls contact each other along an interface between the bottom edge of the top block component and the top edge of the bottom block component and define horizontally disposed octagonal sockets and horizontally disposed hexagonal sockets.

2. The system of claim 1 further including an octagonal tube having an interior surface and an exterior surface, the octagonal tube shaped to interchangeably fit within each of the vertically disposed octagonal sockets and the horizontally disposed octagonal sockets.

3. The system of claim 2 wherein the exterior surface the octagonal tube includes a raised rib extending in the longitudinal direction of the octagonal tube.

4. The system of claim 1 wherein each of the horizontally disposed octagonal sockets and the vertically disposed octagonal sockets includes a stepped internal area that decreases at an octagonal ledge.

5. The system of claim 1 wherein the top wall of the top block component and the bottom wall of the bottom block component are spaced apart and define a cavity for a battery or a motor.

6. The system of claim 1 wherein: the bottom edge of the top block component includes a projection and a recess and wherein the top edge of the bottom block component includes a projection and a recess, and the top block component projection snap fits within the bottom block component recess and the bottom block component projection snap fits within the top block component recess.

7. A system of interlocking blocks, wherein the system comprises:

first and second blocks, each of the first and second blocks including:

a top block component including a top wall and a first plurality of sidewalls extending orthogonally from the top wall to a bottom edge, and

wherein the top wall of the top block component and the bottom wall of the bottom block component include vertically disposed octagonal sockets and vertically disposed hexagonal sockets, and wherein the first plurality of sidewalls and the second plurality of sidewalls abut each other and define horizontally disposed octagonal sockets and horizontally disposed hexagonal sockets; and

an octagonal snap-fit connector to removably join the first block to the second block, wherein the octagonal snap-fit connector is received within the horizontally disposed octagonal sockets of the first and second blocks or within the vertically disposed octagonal sockets of the first and second blocks.

8. The system of claim 7 wherein the octagonal snap-fit connector includes a raised rib extending in the longitudinal direction of the octagonal snap-fit connector.

9. The system of claim 7 wherein:

the vertically disposed octagonal sockets and the horizontally disposed octagonal sockets define a depth as measured from an outer block surface to an interior ledge; and

the octagonal snap-fit connector includes a length that is between one and two times the depth of the vertically disposed octagonal sockets and the horizontally disposed octagonal sockets.

10. The system of claim 7 wherein the top wall of the top block component and the bottom wall of the bottom block component are spaced apart and define a cavity for a battery or a motor.

11. The system of claim 7 wherein the octagonal sockets define a cross-sectional area that is greater than a cross-sectional area defined by the hexagonal sockets.

12. The system of claim 7 wherein the octagonal sockets include a stepped internal area that decreases from a first area to a second area at an octagonal ledge.

13. The system of claim 7 wherein the hexagonal sockets include a stepped internal area that decreases from a first area to a second area at a circular ledge.

14. The system of claim 13 further including an octagonal rod that traverses entirely through one of the first and second blocks.

15. The system of claim 14 wherein the octagonal rod defines a plurality of transverse holes having an area that is equal to the second area of the hexagonal sockets.

16. The system of claim 7 wherein the hexagonal sockets are sized to receive a 1/4 inch thread diameter nut to secure the top block component to the bottom block component.

17. The system of claim 7 wherein the top block component and the bottom block component cooperate to define an internal cavity sized to receive a threaded nut, the threaded nut being adapted to capture a fastener originating from outside of the top block component and the bottom block component.

18. The system of claim 7 further including a peg inserted into overlapping openings in the top block component and the bottom block component to prevent relative rotation therebetween.

19. An angled interlocking block comprising:

an outer wall including a curved portion and first and second planar portion extending from the curved portion, the outer wall defining a first plurality of octagonal sockets and a first plurality of hexagonal sockets; and

an inner wall including first and second planar portions that abut each other at a corner, the inner wall defining a second plurality of octagonal sockets that are aligned with the first plurality of octagonal sockets, the inner wall further defining a second plurality of hexagonal sockets that are aligned with the first plurality of hexagonal sockets.

20. The angled interlocking block of claim 19 wherein the first and second planar portions of the inner wall converge at an angle.

21. The angled interlocking block of claim 19 wherein the first and second planar portions of the inner wall converge at an acute angle, a right angle, or an obtuse angle.

22. A system of interlocking blocks, wherein the system comprises:

first and second foam blocks including a top wall and a first plurality of sidewalls extending orthogonally from the top wall to a bottom wall, the top wall and the bottom wall including an array of vertically disposed polygonal sockets, and the side wall including an array of horizontally disposed polygonal sockets; and

an octagonal snap-fit connector to removably join the first foam block to the second foam block, wherein the octagonal snap-fit connector is received within the horizontally disposed polygonal sockets of the first and second blocks or within one of the vertically disposed polygonal sockets of the first and second blocks.

23. The system of claim 22 wherein the first and second foam blocks are formed from a closed cell foam or an open cell foam.

24. The system of claim 22 wherein the array of vertically disposed polygonal sockets and the array of horizontally disposed polygonal sockets are octagonal sockets.

25. The system of claim 22 wherein the octagonal snap-fit connector includes an octagonal tube.

26. A system of interlocking blocks comprising:

a first u-shaped block and a second u-shaped block, each of the first u-shaped block and the second u-shaped block including first and second yoke arms and an upper major surface opposite a lower major surface, the upper major surface and the lower major surface defining a plurality of octagonal openings and a plurality of hexagonal openings; and

a cross having four orthogonal trunnions, wherein a first pair of the four orthogonal trunnions are pivotably attached to the first and second yoke arms of the first u-shaped block and wherein a second pair of the four orthogonal trunnions are pivotably attached to the first and second yoke arms of the second u-shaped block, such that the cross comprises a trunnion joint between the first u-shaped block and the second u-shaped block.

27. The system of claim 26 wherein each of the plurality of octagonal sockets includes a stepped internal area that decreases at an octagonal ledge.

28. The system of claim 26 wherein each of the plurality of hexagonal sockets includes a stepped internal area that decreases at a circular ledge.