WO2024133861A1 - Modular toy construction system connectors - Google Patents

Modular toy construction system connectors Download PDF

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Publication number
WO2024133861A1
WO2024133861A1 PCT/EP2023/087550 EP2023087550W WO2024133861A1 WO 2024133861 A1 WO2024133861 A1 WO 2024133861A1 EP 2023087550 W EP2023087550 W EP 2023087550W WO 2024133861 A1 WO2024133861 A1 WO 2024133861A1
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WO
WIPO (PCT)
Prior art keywords
connector
functional
carrier
construction system
toy construction
Prior art date
Application number
PCT/EP2023/087550
Other languages
French (fr)
Inventor
Kati Teige Gonzales FRIBORG
Janus Juul Rasmussen
Kathrine Hagen RASMUSSEN
Steffen DUUS
Tobias MUNTHE
Original Assignee
Lego A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lego A/S filed Critical Lego A/S
Publication of WO2024133861A1 publication Critical patent/WO2024133861A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63H—TOYS, e.g. TOPS, DOLLS, HOOPS OR BUILDING BLOCKS
    • A63H33/00—Other toys
    • A63H33/04—Building blocks, strips, or similar building parts
    • A63H33/06—Building blocks, strips, or similar building parts to be assembled without the use of additional elements
    • A63H33/08—Building blocks, strips, or similar building parts to be assembled without the use of additional elements provided with complementary holes, grooves, or protuberances, e.g. dovetails
    • A63H33/086—Building blocks, strips, or similar building parts to be assembled without the use of additional elements provided with complementary holes, grooves, or protuberances, e.g. dovetails with primary projections fitting by friction in complementary spaces between secondary projections, e.g. sidewalls
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63H—TOYS, e.g. TOPS, DOLLS, HOOPS OR BUILDING BLOCKS
    • A63H33/00—Other toys
    • A63H33/04—Building blocks, strips, or similar building parts
    • A63H33/06—Building blocks, strips, or similar building parts to be assembled without the use of additional elements
    • A63H33/062—Building blocks, strips, or similar building parts to be assembled without the use of additional elements with clip or snap mechanisms

Definitions

  • the invention relates to a modular toy construction system comprising a first construction element and a second construction element, the first construction element comprising a first connector, and the second construction element comprising a second connector:
  • the first and second connectors are configured for connecting the first and second construction elements to each other.
  • one construction element has an elongate connector having a cross-shaped cross-sectional shape.
  • Another construction element may have a corresponding receiving part in the form of a recipient space having a likewise cross-shaped cross-sectional shape, where the walls of the cross-shaped recipient space are configured to press on the cross shaped elongate connector of the first construction element, such that a press-fit/pressure fit is provided.
  • a modular toy construction system comprising a first construction element and a second construction element, the first construction element comprising a first connector and the second construction element comprising a second connector, the first and second connectors being configured for connecting the first and second construction elements to each other in a coupling direction
  • the first connector comprises at least two pairs of connector surfaces, where the two connector surfaces of each pair of connector surfaces are formed in parallel to each other, wherein the connector surfaces of one of the two pairs of connector surfaces on the first connector are formed at an angle relative to the connector surfaces of the other of the two pairs of connector surfaces on the first connector
  • the second connector comprises a receiving part having a cross- sectional shape relative to the coupling direction mating with a cross-sectional shape of the first connector, and configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces of the first connector
  • the receiving part of the second connector comprises a set of carrier surfaces each one carrier surface being configured to be adjacent to and facing a specific one of the connector surfaces on the first
  • a further pair of functional surfaces may be arranged on one of the two pairs of carrier surfaces, and in line with one other pair of functional surfaces in a direction perpendicular to the coupling direction.
  • the transitions have substantially the same elevation above the carrier surface.
  • the carrier surface of the receiving part of the second connector surrounds the functional surface.
  • the size of the functional surface is less than 20% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 10% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 5% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 2% of the size of the carrier surface.
  • Fig. 3C is a sectional view of the second construction element shown in Fig 3A, along B-B in Fig 3A;
  • Fig. 5C is a sectional view of the second construction element shown in Fig 5A, along B-B in Fig 5A;
  • Fig. 6B is a sectional view of the second construction element shown in Fig 6A, along A-A in Fig 6A;
  • Fig. 7A in a front view, shows yet another second toy construction element having a cross shaped second connector with functional surfaces according to an embodiment of the invention, the second connector being configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C;
  • the body part 3 of the construction elements 2A, 2B comprises sidewalls 6A, 6B, 6C, and 6D.
  • Each of the sidewalls 6A, 6B, 6C, and 6D are configured with a lowermost edge 7 that forms a resting surface for the construction elements 2A, 2B.
  • Construction elements 2A, 2B of the type shown in Fig. 1A-D further comprises a set of cylinders 911 extending downward from a lower surface 912 of a wall 913 connection all of the sidewalls 6A-D. Between the inner surfaces 916 of the sidewalls 6A-D and outer surfaces of the one or more cylinder 911 , a set of knob receiving openings 902 are formed.
  • the knobs 901 and the knob receiving openings 902 are configured for cooperating to releasably attach to each other in an interference fit/pressure fit. They are examples of complimentary connectors 900.
  • Construction elements 2A, 2B of the type shown in Fig. 1 are connected to each other by the sidewalls 6A, 6B, 6C, and 6D on the uppermost construction element 2A being pressed outwards, when the sidewalls 6A, 6B, 6C, and 6D are pressed down on the coupling studs 901 on the lowermost construction element 2B, following which, the sidewalls 6A-D, and outer surfaces 914 of the cylinders 911 press against the cylindrical outer surfaces 910 of the coupling studs 901 on the lowermost construction element 2B.
  • knobs 910 may connect to a tube connector 20.
  • Other types of cylindrical connectors 900 similar to for example knobs 901, are examples of a first connector 41, connectable to a second connector 42, to which functional surfaces 100, 200, 300 formed on islands according to the invention may be applied. This will be described below. It will be appreciated that construction elements as described above may further comprise first connectors 41 and/or second connectors 42 as described in the following, or that they may be connected to other first construction elements 11 or second construction element 12 comprising such first connectors 41 and/or second connectors 42.
  • the two pairs of connector surfaces 60 are configured for preventing translation of the first connector 41 relative to the a second connector 42, when connected, in two of three dimensions. Therefore, correspondingly, the second connector 42 comprises a receiving part 50 having a cross-sectional shape, which is configured for mating with a cross-sectional shape of a corresponding first connector 41.
  • the receiving part 50 of the second connector 42 is configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces 60 of the first connector 41.
  • Fig. 2C in a perspective view shows a prior art cross-shaped first connector 41 of a first toy construction element 11 , i.e. the first connector has a cross shaped, cross sectional shape.
  • a first connector 41 as shown in Fig. 2C when inserted into the receiving part 50 of the second connector 42 of Fig. 2B may NOT be translated relative to the second connector 42, once it has been coupled/attached, since a translation of the first connector 41 in the direction opposite to the arrow Dj will disengage the first and second connectors 41 , 42.
  • the second connectors 42 shown in Figs. 2A-B have in common that they are both configured for forming a connection with a cross shaped first connector 41 for example as shown in Fig. 2C. They differ in that a first connector 41 inserted in the second connector shown in Fig 2A is not locked from translational movement in the coupling direction, Dj, because there is no end stop.
  • a first connector 41 inserted into the second connector 42 shown in Fig. 2B may only be inserted to the bottom thereof as defined by a separating wall between the second connector 42 and the perpendicularly arranged tube 12’. It will be appreciated that in both of the second connectors 42 of Figs. 2A and 2B, any inserted first connector 41 is locked from rotation in all three rotational directions.
  • each arm has two side surfaces and an arm end surface 61.
  • the side surfaces are used as connector surfaces 60 in the sense described above, in that they may be used to make contact with surfaces of the second connector 42.
  • at least two pairs of connector surfaces 60 may be formed on the first connector 41.
  • Two pair of connector surfaces 60 are formed on each arm, one pair on each side of the intersection between the arms.
  • the connector surfaces 60 of each pair faces away from each other.
  • the connector surfaces 60 of any one pair are formed parallel to each other.
  • the connector surfaces 60 of the pairs of connector surfaces 60 on one arm are formed perpendicularly to the connector surfaces 60 of the each pair on the intersecting arm.
  • the first connector 41 in this case (Figs. 2C-D) has eight connector surfaces 60.
  • the arms of the L or V shaped first connector 41 need not be the same length.
  • Fig. 2F shows another example of a first connector 41.
  • the first connector 41 shown in Fig. 2F has a rectangular cross-shape.
  • two pairs of connector surfaces 60 may be formed om the first connector, each connector surface 60 of a pair facing away from each other.
  • each connector surface 60 of a pair are formed parallel to each other.
  • the connector surfaces 60 of one pairs of connector surfaces 60 are formed perpendicularly to the connector surfaces 60 of the other pair of connector surfaces 60.
  • the contact surfaces 60 of a pair may not be formed parallel to each other.
  • the second connectors generally have contact surfaces formed as mating surfaces to the connector surfaces 60 of the first connector 41 , such that the contact surfaces on the second connector 42 are shaped and sized to match the connector surfaces 60 of the first connector 41.
  • the function and quality of the connections between cross-shaped rods/shaft and cross-shaped second connectors 42, as described above are very sensitive to the type of material used for the making the connection, and to the overlap dimensions such as well as the geometrical inertia of the second construction element 12 to which they form part, etc., and that this puts demands for extreme tolerances in the production of such cross shaped connectors.
  • the present invention relates to a modular toy construction system 10 comprising a first construction element 11 and a second construction element 12, where the first construction element 11 comprises a first connector 41 , for example as described in connection with Figs. 2A-G, and where the second construction element 12 comprises a second connector 42, which is configured for releasably connecting to the first connector 41 in a press fit connection/pressure fit connection.
  • the first and second connectors 41 , 42 are configured for connecting the first and second construction elements to each other in a coupling direction, Dj.
  • a first connector for the invention may take any of the cross-sectional shapes described above.
  • the first connector 41 in the general case comprises at least two pairs of connector surfaces 60, where the two connector surfaces 60 of each pair of connector surface 60 are formed such that they are facing away from each other on the first connector 41. Further, the first connector 41 is formed such that connector surfaces 60 of one pair of connector surfaces 60 forms an angle relative to at least one pair of the other pairs of connector surfaces 60.
  • the second connector 42 comprises a receiving part 50 having a cross sectional shape mating with a cross-sectional shape of the first connector 41.
  • the receiving part 50 of the second connector 42 may further comprise a set of carrier surfaces 51.
  • the receiving part 50 is configured such that, for each connector surface 60, one carrier surface 51 is adjacent to each of the connector surfaces 60 on the first connector 41 , when the first connector 41 and the second connector 42 are connected to each other.
  • the number and location of carrier surfaces 51 matches the number and location of the connector surfaces 60.
  • the second connector 42 in the general form, comprises two pairs of carrier surfaces 51 , where the two carrier surfaces 51 of each pair of carrier surfaces 51 are formed in parallel to each other.
  • the carrier surfaces of one of the two pairs of carrier surfaces on the second connector are formed at an angle relative to the carrier surfaces of the other of the two pairs of carrier surfaces on the second connector.
  • the receiving part 50 of the second connector 42 further comprises a set of functional surfaces 100, for example as shown in Figs 3A-C.
  • the functional surfaces
  • Each functional surface 100 is formed as a top surface of an island 101 , the island
  • the receiving part 50 of the second connector 42 may, in some embodiments, be configured such that, when the first and second connectors 41 , 42 are connected to each other, the one or more connector surfaces 60 of the first connector 41 contacts the second connector 42 at the functional surfaces 100 only.
  • One embodiment of such a second connector 42 is shown in Figs. 3A-C.
  • Fig. 3A in a front view, shows a second construction element 12 having a cross shaped second connector 42 formed therein, and with functional surfaces 100 according to the invention. Each functional surface 100 is formed on an island 101 lifting the functional surface above the carrier surface.
  • the second connector 42 of Figs. 3A-C is configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C.
  • the second construction element 12 for simplicity is formed as a simple cubical element. It will be appreciated that the second construction element 12 may take many other shapes and forms. For example, the second construction element 12 may be formed like the second construction element 12 shown in Fig. 2A, or as a building block as illustrated in Figs. 1A-D.
  • the second connector 42 shown in Figs. 3A-C is of the type shown in Fig. 2A, where the first connector 41 is allowed to translate after coupling. It will also be appreciated, that Fig. 3A-C may also be representative for a second type connector 42 as in Fig. 2B, where an end wall could be envisaged in one of the ends of the receiving part 50. Such a second connector 42 with an end wall 54 and an end carrier surface 55 is illustrated in Figs. 7A-C.
  • the second connector 42 may be equipped with a number of functional surfaces 100 formed in pairs across from each other.
  • the functional surfaces 100 of a pair of functional surfaces can also be said to face each other.
  • Each of the functional surfaces 100 is formed on an island 101, raised above a carrier surface 51 of the second connector 42.
  • the functional surfaces are preferably formed in pairs of functional surfaces 100, 200, 300.
  • the one functional surface 100, 200, 300 of each pair of functional surfaces 100, 200, 300 is formed on a first carrier surface 51.
  • the other functional surface 100, 200, 300 of the same pair of functional surfaces 100, 200, 300 is formed on a second carrier surface 51 .
  • the first carrier surface and the second carrier surface of the pair are arranged in parallel to each other.
  • first carrier surface and the second carrier surface are arranged on opposite sides of the receiving part in a direction perpendicular to the coupling direction, Dj.
  • the carrier surfaces are formed on a female part, why the receiving part forms a cavity, where the carrier surfaces are formed around the cavity, and defines the cavity.
  • one of the two functional surfaces 100, 200, 300 of a pair of functional surfaces 100, 200, 300 is arranged oppositely to the other of the same pair of functional surfaces 100, 200, 300 in a direction perpendicular to the coupling direction Dj.
  • the functional surfaces 100 may be of two types. Thus, a functional surface 100 may be either a pressure surface 200 or a datum surface 300. The features and function of pressure surfaces 200 and datum surfaces, 300 respectively, will be described in further detail in connection with Figs. 4A-C below.
  • the receiving part 50 of the second connector 42 shown in Figs. 3A-C has a cross shaped cross-sectional shape (in a direction perpendicular to a longitudinal direction of the receiving part 50 of the second connector 42, which is parallel to the coupling direction Dj (which is shown in Fig. 3B), and represented by the z- axis in Figs. 3A-C).
  • the receiving part 50 comprises two crossed or intersecting arms. The two arms, in the shown case, intersect at the middle of each arm. It will however be appreciated that a similar function may be obtained if the intersection is displaced from the middle of one or both arms (and the corresponding second connector is configured to match the resulting cross-sectional shape).
  • a set of pressure surfaces 200 is formed on the left hand side of Fig. 3A.
  • a pair of datum surfaces 300 is formed on the right hand side of Fig. 3A.
  • two pairs of datum surfaces 300 are formed on the top of Fig. 3A.
  • Each of the functional surfaces 100 pressure surfaces 200 or datum surfaces 300 is configured as described below in connection with Figs. 4A-C.
  • Fig. 3B is a sectional view along A-A in Fig 3A, of the second construction element 12 in Fig 3A
  • Fig. 3C is a sectional view of the second construction element 12 shown in Fig 3A, along B-B in Fig 3A.
  • two pairs of functional surface 100 may be formed in line or in series one after the other. It will be appreciated that, in the sections through the second connector 42, only one of the two functional surfaces 100 of a pair of functional surfaces 100, 200, 300 are visible.
  • Fig. 3B two pairs of pressure surfaces 200 on the left hand side of the figure can be seen, each pair being represented by one of the two pressure surfaces 200 of the pair of pressure surfaces 200, which can be seen in line with each other in the direction of the coupling direction Dj.
  • Fig. 3B there is one pair of datum surfaces 300, represented by one of the two datum surfaces 300 of the pair of datum surfaces 300.
  • Fig. 3C two pairs of datum surfaces 300 in the upper part of the figure can be seen, each pair being represented by one of the two datum surfaces 300 of the pair of datum surfaces 300, which can be seen in line with each other in the direction of the coupling direction Dj.
  • Fig. 15A and Fig. 16 also indicates a coupling direction, Di, in which the first connector 41 is to be inserted into the second connector 42, or in which the second connector 42 is inserted into first connector 41 for bringing the one or more functional surfaces 100 into contact with the one or more connector surfaces 60.
  • the second connector 42 comprises a receiving portion 50.
  • the receiving portion 50 comprises a set of carrier surfaces 51. Some or all of the carrier comprises functional surfaces 100.
  • Such functional surfaces 100 forms part of a modular toy construction system 10 according to the invention, where they may replace the traditional contact surfaces on second connectors 42 of second construction elements for a modular toy construction system 10 according to the invention.
  • the receiving portion 50 of the second connector 42 may be a male part or a female part. In the shown embodiments, however, the receiving portion 50 of the second connector 42 is exemplified as a female part, the receiving portion 50 forming cavity configured for receiving a first connector 41 in the form of a male part into the cavity.
  • the receiving portion 50 of the second connector 42 may be a male part, having the one or more functional surfaces provided on an outer surface, and where the first part 41 comprise a cavity configured for receiving the male second connector there in to.
  • the functional surfaces may be either pressure surfaces 200 or datum surfaces 300.
  • Pressure surfaces 200 are arranged and dimensioned on the second connector 42 in such a way that the pressure surface 50 will provide a pressure on a connector surface 60 of a connected first connector 41.
  • pressure surfaces 200 are arranged and dimensioned on the second connector 42, such that the pressure surface 200 will provide a local deformation of the connector surface 60 of a connected first connector 41. This deformation will only occur in the immediate vicinity of the pressure surface 200.
  • Datum surfaces 300 are arranged on and dimensioned on the second connector 42 in such a way, that the datum surfaces 300 do not provide a pressure on the corresponding connector surface 60 of a connected first connector 41 (when connected), but only provide a snug fit, such that datum surfaces 300 may provide guide surfaces for locating the first connector correctly relative to the pressure surfaces 200.
  • the one or more connector surfaces 60 of the first connector 41 only contacts the second connector 42 at the two or more functional surfaces 100, when the first connector 41 and the second connector have been connected to each other.
  • each of the functional surfaces 100 are formed on an island 101 , such that the functional surface 100 is raised from - or extending away from - the carrier surface 51 of the receiving part 50, in the sense that the carrier surface 51 may extends 360° around the functional surface 200.
  • the functional surface is formed as a top surface, or the uppermost part of the island 101 , relative to the carrier surface 51 on which the island 101 is formed.
  • the functional surface 100 is a datum surface 300
  • a gap or clearance between the first connector 41 and the second connector 42 i.e. between the connector surface 60 and the carrier surface 51
  • the island 101 on which the datum surface 300 is provided i.e. between the connector surface 60 and the carrier surface 51
  • a gap or clearance between the first connector 41 and the second connector 42 i.e. between the connector surface 60 and the carrier surface 51
  • the island 101 on which the pressure surface 200 is provided i.e. between the connector surface 60 and the carrier surface 51
  • the deformation such as a local deformation, of a portion of the first connector 41 will cause the connector surface 60 and the carrier surface 51 to be connected in an interference fit/pressure fit/press fit.
  • the carrier surface 51 is preferably not in contact with connector surface 60 the first connector 41.
  • Figs. 4A-C only a portion of the second connector 42 and the second construction element 12 is visible. However, it will be appreciated that the island 101 with a functional surface 100 may be part of a second connector 42 of a second construction element 12 of a modular toy construction system 10 as mentioned above.
  • the first and second connectors 41, 22 are configured for connecting the first and second construction elements 11, 12 to each other, in the sense that they are shaped and sized to be complimentary to each other.
  • the first connector 41 may preferably be formed as an integral part of the first construction element 11.
  • first connector 41 may alternatively be a separate component attachable to the first construction element 11 , preferably such that the first connector 21 is unreleasbly attached to the first construction element 11.
  • first connector 41 may be construed as a first construction element 41 in its own right. An example of the latter is shown in Fig, 2C.
  • the second connector 42 may preferably be formed as an integral part of the second construction element.12. However, in principle the second connector 42 may alternatively be a separate component attachable to the second construction element 12, preferably such that the second connector 22 is unreleasbly attached to the second construction element 12.
  • Fig. 4A indicates a coupling direction, Di, in which a first connector 41 is to be inserted into the second connector 42, for bringing the two or more functional surfaces 100 into contact with the one or more connector surfaces 60 of a first connector 41.
  • Pressure surfaces 200 are preferably arranged on the receiving part 50 of the second connector 42, such that they are arranged in pairs. A pair of pressure surfaces 200 face each other.
  • Datum surfaces 300 are preferably also arranged on the receiving part 50 of the second connector 42, such that they are arranged in pairs. A pair of datum surfaces 300 face each other.
  • each pressure surfaces 200 is formed on an island 101, which is formed on a carrier surface 51 of the receiving part 50 of the second connector 42.
  • the islands 101 are preferably formed as integral parts of the second connector 42.
  • each datum surfaces 300 is formed on an island 101 , which is formed on a carrier surface 51 of the receiving part 50 of the second connector 42.
  • the islands 101 are preferably formed as integral parts of the second connector 42.
  • the number of pressure surfaces 200 and the number of datum surfaces 300 may vary depending on the connector.
  • the number of pressure surfaces 200, or more particularly the number of pressure connector 200 pairs, and the configuration of the pressure surface geometry defines the clutch force or drawing force of the connection between the first connector 41 and the second connector 42.
  • the arrangement of the datum surfaces 300, or more particularly the number of datum surface pairs, defines the stability of the connection to prevent misalignment and secures that the pressure surface 200 engage the connector surfaces 60 of the first connector 41 correctly.
  • the islands 101 comprising a functional surface 100 may elevate the functional surface 1000 to a height, h, above the carrier surface 51 of the receiving part 50 of the second connector 50.
  • the shape of the islands 101 on which the functional surfaces 100 are located are formed in such a way that the functional surface 100 (pressure surface 200 or datum surface 300) smoothly transcends into an inlet surface 400.
  • the inlet surface 400 may smoothly transcend into the carrier surface 51.
  • the term “smoothly transcending” or “smoothly transitioning” should be understood such that the transition between the functional surface 100 and the inlet surface 400, and/or between the inlet surface 400 and the carrier surface 51 , has a well-defined tangent in all points. The transition is tangential. This means that there are no separating edges between the surfaces.
  • the inlet surface 400 forms an angle to the functional surface 100.
  • the inlet surface 400 serves to guide the first connector 41 towards the functional surface 100, with minimum introduced material strain, during the attachment of the first and second connectors 41, 42, such that the functional surface 100 is not damaged during repeated attachments and detachments. This may be provided by curving the inlet surface.
  • the height, hi, of the inlet surface (above the carrier surface 51) in the coupling direction towards the functional surface 100 preferably forms a curve.
  • the inlet surface 400 is formed such that when connecting the first and second connectors 41, 42, the shear on the inlet surface 400, provided by first connector 41 on the inlet surface 400 is constant over the travel of the first connector 41 on the inlet surface 400 from the inlet of the inlet surface 400 to the transition to the functional surface 100.
  • This may be provided by curving the inlet surface 400 such that the force induced by first connector on the inlet surface is kept constant in the coupling direction for connecting the first connector 41 to the receiving part 50 of the second connector 42 towards the functional surface 100.
  • the inlet surface 400 is inclined relative to the coupling direction, Di, where an angle of inclination varies along the coupling direction, Di.
  • the inclination angle initially gradually increases along the coupling direction towards the functional surface 100, and subsequently gradually decreases along the coupling direction, Di, approaching the functional surface 100.
  • the angle of the inlet surface relative to a plane defined in the coupling direction varies continuously from the end of the inlet surface opposite to the pressure surface in the coupling direction to the pressure surface.
  • the curve may be defined by the following formula where:
  • h is the height of the curve, i.e. the elevation or height of the inlet surface 400 over the carrier surface, where it transcends into the functional surface 100, and
  • the island 101 with a functional surface 100 is shown in section in Figs. 4B and Fig.16.
  • the island 101 is shown in a view in order to show the transitions 600 between the inlet surfaces 400, 401 , 402 and the functional surface 100 in more detail.
  • the inclination of the inlet surface 400, 401 , 402 appear steeper than they would in real islands. Further the length and height proportions are not representative.
  • At least the transition 600 connecting the functional surface 100 with the inlet surface 400 that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100 has a radius of curvature, RT, about an axis perpendicular to the coupling direction Di.
  • the functional surface 100 may further has radius of curvature, Rp.
  • the radius of curvature, RP of the functional surface 100 is infinite, «, but in other embodiments, the functional surface 100 may be curved thus having a finite radius of curvature, R P .
  • the radius of curvature, R T , of the transition 600 is smaller than a corresponding radius of curvature, R P , of the functional surface 100.
  • both transitions 600 has a radius of curvature, R T .
  • the radius of curvature, R T , of the two transitions 600 need not be the same.
  • the functional surface 100 in any case has a length, L3, defined in a direction parallel to the coupling direction, Dj.
  • the length, L3 of the functional surface 100 may be defined between the transitions 600 to each of the inlet surfaces 400.
  • the distance, L3, of the functional surface 100, between the transitions 600 in the coupling direction Dj is larger than the corresponding length of each of the transitions 600, and at least larger than the corresponding length of the transition 600 connecting the functional surface 100 with the inlet surface 400 that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100.
  • the height, h, or elevation above the carrier surface 51 , of the transitions 600 at either side of the functional surface 100 is substantially the same.
  • the transitions 600 may form an edge.
  • any “edge” will be provided as a (narrow) surface between the two surfaces meeting in the edge.
  • a “real life” edge will have or constitute a transition 600 or transition surface as mentioned above.
  • the inlet surfaces 400 preferably forms an angle relative to the functional surface 100, i.e. they are inclined relative to the functional surface 100, such that the inlet surfaces 400 may form ramps leading onto the functional surface 100.
  • the island 100 may further comprise a side surface 700 formed adjacent to the pressure surface in a direction perpendicular to the coupling direction, and between the functional surface 100 and the carrier surface 51.
  • the side surface 700 is connected to the functional surface 100 via a transition.
  • this transition between the functional surface 100 and the side surface 700 is smooth.
  • the transition between the functional surface 100 and the side surface 700 is tangential from the functional surface 100 to the side surface 700 in the direction perpendicular to the coupling direction.
  • a side surface 700 as described may be provided adjacent to the functional surface 7000 on both sides of the functional surface 100, in a direction perpendicular to the coupling direction Dj.
  • the configuration of the inlet surfaces 400 prevents or at least reduces damage to the functional surface 100 formed on the island 101.
  • the inlet surface 400 serves to guide the first connector 41 towards the functional surface 100, with minimum introduced material strain, during the attachment of the first and second connectors 41, 42, such that the functional surface 100 is not damaged during repeated attachments and detachments.
  • At least the inlet surface 400, 401 facing the coupling direction is formed such that during the act of connecting the first and second connectors 41 , 42, the shear on the inlet surface 400, 410 provided by the first connector 41 on the inlet surface 400, 401 is constant over the travel of the first connector 41 on the inlet surface 400, 401 from an inlet 405 of the inlet surface 400, 401 to the transition 600 to the functional surface 100.
  • the inlet surface 400, 401 facing the coupling direction Dj is the inlet surface that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100.
  • the feature of constant shear may also apply the opposite inlet surface 400, 402, especially if this inlet surface is also configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100, but also if it is not.
  • At least the inlet surface 400, 401 facing the coupling direction, Dj, may be curved, e.g. as described above.
  • At least the inlet surface 400, 401 facing the coupling direction, Dj may be formed as a segmented surface 400, 401 , 40T, 401 ”.
  • Each segment 401 , 40T, 401 ” of the inlet surface 400, 401 may have it’s own inclination relative to the functional surface 100 and to the carrier surface 51 on which it is formed.
  • a transition is formed between the segments 40T, 401”. Preferably such transition is smooth.
  • each of such segments 40T, 401” of the inlet surface 400, 401 may be curved (have a curvature and a radius of curvature).
  • a catch surface 500 may be formed adjacent to the inlet surface 400 distally relative to the functional surface 100, and at an opening into the receiving part 50 of the second connector 42.
  • the catch surface 500 serves to direct the first connector 41 towards the inlet surface 400 at the beginning of attaching a first connector 41 to a second connector 42.
  • a smooth transition of the inlet surface 400 into the catch surface 500 may be provided.
  • a portion of the carrier surface 51 is provided between the catch surface 500 and the inlet surface 400. In such cases, preferably, the e is made such that the inlet surface smoothly transcends into the carrier surface 51 which again smoothly transcends into the catch surface 500.
  • the islands 101 comprising a functional surface 100 may comprise an inlet surface 400 on two opposite sides of the functional surface 100 in the direction of coupling, Dj.
  • attachment or coupling may be desirable from two opposite ends of a second connector 42, for example in a second connector 42 as shown Fig. 3A-C.
  • an inlet surface 400 is preferably formed at both ends of the functional surface 100, which may serve to guide the first connector 41 towards the functional surface 100 during the attachment of the first and second connectors 41, 42, from two opposite directions. Thereby, the functional surface 100 is not damaged during repeated attachments and detachments.
  • the second inlet surface 400, 402 may be formed as described above.
  • both an island 101 comprising a pressure surfaces 200 and an island 101 comprising a datum surface 300 may be formed as described above for functional surfaces in general.
  • the islands 101 having datum surfaces 300 may be formed such that the inlet surface (or inlet surfaces 400 are simple ramps having a uniform angle relative to the coupling direction Dj over the entire length of the inlet surface 400.
  • a further inlet surface 400 opposite to a first inlet surface seen in the direction of coupling, Di forms an undercut 402.
  • An undercut 402 allows to control the surface area of the functional surfaces 100, particularly pressure surfaces 200, together with the width, W3, of the functional surfaces 100, and serves the function of reducing or eliminating a spring-back effect of the connection between the first connector 41 and the second connector 42.
  • Spring-back effect is understood as an angled reaction force pushing the interfaces apart. This phenomenon is very sensitive to geometrical misalignment and has a significant impact on experienced functionality and the maximum overlap of the pressure surfaces.
  • the carrier surface 51 may extends completely, i.e. 360°, around the functional surface 100, such as the island 101 shown in the right hands side of Fig. 13B. In other embodiments, the carrier surface 51 may extends partly around the functional surface 100.
  • An intermediary raised surface 800 may formed between islands that are formed in line in the coupling direction.
  • the intermediary raised surface 800 is elevated above the carrier surface 50 of the second connector 20.
  • the intermediary raised surface 800 has a height above the carrier surface 50, which is smaller than the height of the functional surface 100, 200, 300 and larger than or equal to the smallest height of the neighbouring inlet surface 400, 402.
  • the geometrical principles applied in the interface are generic and, therefore, not limited by geometrical sizes or material selection. Dimensioning for target functionality is more easily obtained than for the prior art pressure surfaces by faster dimensioning of functional surfaces 100, in particular pressure surfaces 200, ensuring a local deformation relative to the stiffness of the first and second connectors 41 , 42 depending on e.g. material properties and material thickness.
  • the desired functionality (measured in drawing force) is created by the press fit connection with overlap on the protruding pressure surfaces 200 (local deformation control), and through friction between the interfacing surfaces - protruding pressure surfaces 200 and the connector surfaces 60 of the first connector 41 , and the spring-back effect is eliminated with the implemented undercut 402.
  • the datum surfaces 50 ensure desired positioning and grid compatibility without affecting functionality.
  • the number of pressure surfaces 200 and the number of datum surfaces 300 may vary depending on the connector.
  • the number of pressure surfaces 200 and the geometry thereof may vary in order to secure a desired clutch force between the first and second connector 41 , 42, depending on the shape, hardness, dimensions, etc. of the first connector 41 and the second connector and the construction elements 11, 12 on which they are formed.
  • the shape of the functional surface 100 may be determined.
  • the functional surfaces 100 may be convex, concave or planar, i.e. the radius R1 of the functional surface may vary.
  • the functional surface may be rectangular, circular or oval.
  • the functional surfaces 100 extends in two dimensions, such that they have a length, L3, in the direction of coupling Di and a width, W3, perpendicular to the direction of coupling, Di as exemplified in e.g. Fig. 4A-B.
  • the length L3 and the width W1 are non-zero values. It is noted, that the length L3 and width W3 of a functional surface 100 may be major and minor axes of an ellipse (not shown).
  • the length, L3, and the width, Wi,of the functional surfaces 100, and at least of the one or more pressure surfaces 200, are non-zero.
  • the island 101 on which the functional surface 100 is formed, extends in two dimensions, such that they have a length, L0, in the coupling direction Dj and a width, W0, perpendicular to the coupling direction, Dj as exemplified in e.g. Fig. 4A- B. It is noted, that the length L0 and width W0 of an island may be major and minor axes of an ellipse(not shown).
  • An island 101 having a functional surface 100 has a length L0 in the coupling direction Di for attaching a first connector 41 .
  • the length, L0 is defined as the distance in the coupling direction Di between a first met inlet surface 400 (or from the associated catch surface 500, if present) across the inlet surface 400, the functional surface 100 and an opposite inlet surface 400 (undercut 402) and an associated catch surface 500, if present.
  • the length L o of an island having a functional surface 100 is smaller than the total length of the connection between the first connector 41 and the second connector 42, as defined by the length of the carrier surface 51 in the direction of coupling, Di. More preferably, the length, L0, of the island is smaller than half of the total length of the connection between the first connector 41 and the second connector 42. In some embodiments, the length, L0, of the island is smaller than one third of the total length of the connection between the first connector 41 and the second connector 42.
  • the length, Lo ot the island is preferably larger than one fifth of the total length of the connection between the first connector 41 and the second connector 42.
  • the functional surfaces 100 has a radius, R1 , a length L3 and a width W3.
  • the radius, R1 , the length L3 and the width W3 are dimensioned to provide a predetermined pressure on the connector surfaces 60 of the first connector 41 at a predetermined location of the connector surface 60 of the first connector 41.
  • the inlet surface 400 may be a straight planar surface, or in not shown embodiments comprises a curved surface portion, at least in the direction of the coupling direction, Di.
  • the functional surfaces 100 are arranged in pairs, where in a pair, one functional surface 100 is arranged on an island 101 on each of two mutually facing (opposed) carrier surfaces 51.
  • a pair of functional surfaces 100, 200, 300 is provided on opposed carrier surfaces 51 of the receiving part 50 of the second connector 42.
  • a second connector 42 for a modular toy construction system 10 such as the second connector 42 shown in Fig. 3A-C
  • at least five pairs of diametrically opposed functional surfaces 100, 200, 300 are distributed on the carrier surfaces 51 of the receiving part 50 of the second connector 42.
  • a first connector 41 coupled to the second connector 42 will be locked against rotation in all three dimensions relative to the second connector 42.
  • the first connector 41 will be locked from translational movement in two directions/dimensions (x and y directions/dimensions in the figure), while one translational direction is free (z- direction) in Figs. 3A-C.
  • translation in the z-dimension parallel to the coupling direction, Di may be locked by providing an end wall 54 in the second connector 42, as shown in Figs. 7A-C.
  • the end wall 54 comprises an end carrier surface 55, facing - or forming part of - the receiving part 50, on which the end surface 65 of the first connector 41 may abut when the first connector 41 is coupled to the second connector 42 at the intended position.
  • the end carrier surface 55 of the second connector 42 as shown in Figs. 7A-C 11, may further be provided with an island 101 comprising a functional surface 100. This will allow a more precise location of the first connector 41 when coupled to the second connector 42.
  • the end carrier surface 55 of the second connector 42 may further be provided with more than one island 101 (each island 101 comprising a functional surface 100), such as a pair of islands 101 (each island 101 comprising a functional surface 100).
  • the above mentioned prevention from rotation between a first connector 41 and a second connector in one dimension is provided in the following way:
  • the mutually facing carrier surfaces 51 may be provided with two pairs of functional surfaces 100 arranged in series to each other in a direction parallel with the coupling direction (Di), as exemplified in e.g. Fig. 3B.
  • Fig. 3B only one of the two mutually facing carrier surfaces 51 is seen.
  • the mutually facing carrier surface 51 which is provided with the other of the mutually facing functional surfaces 100, of the two pairs of functional surfaces 100, can be seen in the front view of Fig. 3A, on the left hand side arm, on the upper side of the arm (when oriented as in Fig. 3A). It will be appreciated that when such two pairs of functional surfaces 100 are arranged in linear extension of each other, a first connector inserted therein will abut on the four functional surfaces, and that this will prevent rotation in one dimension (in this example rotation around the y-axis is prevented).
  • a similar arrangement (two pairs of functional surfaces 100 in series in the direction parallel to the coupling direction Dj) may further be provided on a pair of mutually facing carrier surfaces 51 , which are arranged perpendicular to the mutually facing carrier surfaces 51 mentioned in the previous paragraph.
  • a first connector 41 coupled to the second connector of Figs. 3A-C will be locked against, i.e. prevented from, rotation in a second dimension (in this example rotation around the x-axis is prevented).
  • Rotation in the third dimension i.e. about the z-axis, which is here coinciding with the coupling direction Dj (and the longitudinal direction of an inserted first connector 41), may be prevented by adding one more pair of functional surfaces 100 on a pair of mutually facing carrier surfaces 51 in a direction perpendicular to the coupling direction Dj.
  • this is exemplified by the single functional surface 100 on the vertically oriented carrier surface on the right hand side of the figure.
  • the other one functional surface 100 of this pair of functional surfaces 100 can be seen in section in Fig. 3A on the right arm, and (also in a (longitudinal) section) in Fig. 3C on the right hand side of the receiving part 50 of the second connector 42.
  • a slight rotation about the z-axis could be obtained.
  • This could for example be used in a toy construction set of the modular toy construction system 10, to imitate a key (partially) turning in a key hole.
  • omitting one pair of functional surfaces 100 of one of the pairs of functional surfaces arrange in series along the coupling direction (or just one of the functional surfaces 100 of the pair of surfaces.) would allow a slight rotation about the x-axis or y-axis in the figure.
  • This could be for example be used in a toy construction set of the modular toy construction system 10, to imitate a gear stick in a car.
  • the first connector 41 may be formed in a polymer material.
  • a polymer material may be ABS plastic.
  • Forming the first connector in a polymer may allow to form the first connector 41 in e.g. an injection molding process, or for example in an additive manufacturing process, depending among other things on the material choice.
  • the second connector (42) is formed in a polymer material.
  • a polymer material may be ABS plastic.
  • Forming the second connector 42 in a polymer may allow to form the second connector 42 in e.g. an injection molding process, or for example in an additive manufacturing process, depending among other things on the material choice.
  • the islands 101 provided with the functional surfaces 100 are formed integrally with the second connector 42.
  • the functional surfaces 100 may of one of two types, pressure surfaces 200 and datum surfaces 300.
  • Functional surfaces 100 of a pair of functional surfaces 100 are of the same type.
  • a pair of functional surface 100 facing each other are either both pressure surfaces 200 or they are datum surfaces. 300.
  • all of the functional surfaces 100 of a second connector 42 of the invention may be datum surfaces 300. It is clear that, since datum surfaces do not press on the connector surfaces 60 of a first connector 41 (when coupled to the second connector) but is formed match snugly on opposed connector surfaces 60 of the first connector, such as to function only as positioning means, friction between a second connector 42 and a first connector 41 coupled thereto, would be very low, why the connection there between would be unstable. The first connector 41 could easily slip out of the second connector 42.
  • the set of functional surfaces 100 comprises one pair of pressure surfaces 200.
  • a pair of pressure surfaces 200 is configured the same way as above, i.e. the two pressure surfaces 200 of the pair of pressure surfaces 200 are arranged on opposed carrier surfaces 51, i.e. two carrier surfaces 51 facing each other.
  • the two pressure surfaces 200 of the pair of pressure surfaces 200 are configured to provide a local deformation of a connector surface 60 of the first connector 41 when connected. This means that the distance between the two pressure surfaces 200 of the pair of pressure surfaces 200 is smaller than a distance between the two connector surfaces (facing away from each other) of the first connector, which the pressure surfaces engages.
  • At least one pair functional surfaces are pressure surfaces 200.
  • the number of pairs of pressure surfaces may vary, for example according to a desired holding force between the first connector 41 and the second connector. Exemplary embodiments hereof are described below.
  • the pairs of functional surfaces 100, which are not pressure surfaces 200 are datum surfaces 300.
  • Figs 3A-C there are two pairs of pressure surfaces 200.
  • the two pairs of pressure surfaces 200 are arranged in series relative to each other in a direction parallel with the coupling direction (Di), as exemplified in e.g. Fig. 3B, see the left side of Fig. 3B.
  • One pair of the two pairs of pressure surfaces 200 are seen on the left arm seen in Fig. 3A.
  • the other three pairs of functional surfaces 100, in the embodiment shown in Figs. 3A-C are datum surfaces 300.
  • the pressure surface on the left arm
  • the datum surface 300 which can be seen on the top arm and the right arm.
  • Figs 5A-C and Figs. 6A-C show other embodiments, where the number of pairs of pressure surfaces 200 and datum surfaces differ from that of the embodiment in Figs. 3A-C.
  • Fig. 5A which is otherwise identical to the embodiment of Figs. 3A-C, there are four pairs of pressure surfaces 200. Two pairs of the four pairs of pressure surfaces 200 are arranged, as in the embodiment in Fig. 3A. Further, two additional pairs of pressure surfaces 200 are provided in series relative to each other in a direction parallel with the coupling direction (Di), as seen e.g. in Fig. 5CB. As may be appreciated from Fig.
  • a similar arrangement (two pairs of functional surfaces 100 in series in the direction parallel to the coupling direction Dj) of the two additional pairs of pressure surfaces 200 may be provided on a pair of mutually facing carrier surfaces 51 , which are arranged perpendicular to the mutually facing carrier surfaces 51 mentioned in relation to the first two pairs of pressure surfaces 200.
  • the last pair of functional surfaces 100 in this embodiment is a pair of datum surfaces 300.
  • pairs of pressure surfaces 200 are configured to provide pressure on the corresponding connector surfaces 60 of a first connector 41 (when connected), such as by a local deformation thereof, it is clear that increasing the number of pairs of pressure surfaces 200 relative to the number of datum surfaces 300, will increase the friction between the second connector 42 and a first connector coupled thereto, and thereby the holding force there between. In this way designing the relation between the number of pairs of datum surfaces 300 and the number of pairs of pressure surfaces 200, can be used to make connectors having a desired holding force between them.
  • the embodiment shown in Figs 7A-C has the same number of functional surface 100 as the embodiments of Figs. 3A-C, Figs. 5A-C and Figs. 6A-C, and the functional surfaces are located in the same locations.
  • the embodiment shown in Figs 7A-C further has the same distribution of the pressure surfaces 200 and datum surfaces 300 as the embodiment shown in Figs. 5A-C.
  • the embodiment differs from the embodiments of Figs. 3A-C, Figs. 5A-C and Figs. 6A-C in that the second connector 42 comprises an end stop, provided by the wall 54 as described previously.
  • the distribution of pairs of pressure surfaces may further vary.
  • such a second connector may have one pair of pressure surfaces 200 and four pairs of datum surfaces 300, such as the embodiment shown in Figs. 3A-C, or the second connector 42 may have four pairs of pressure surfaces 200 and zero pairs of datum surfaces 300, such as the embodiment shown in Figs. 6A-C.
  • Islands 101 configured to have a pressure surface 200 formed thereon could also be called a pressure island or pressure inducing island.
  • Islands 101 configured with a datum surface 300 thereon could also be called a datum island or a positioning island.
  • first inlet surface having second curvature or second angle relative to functional surface
  • 911 cylinders extending downward from a lower surface of a wall connecting all of the sidewalls of a (brick type) construction element

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Abstract

A modular toy construction system (10) comprising a first construction element (11) and a second construction element (12), the first construction element (11) comprising a first connector (41) and the second construction element (12) comprising a second connector (42), the first and second connectors (41, 42) being configured for connecting the first and second construction elements (11, 12) to each other in a coupling direction (Di), wherein the first connector (41) comprises at least two pairs of connector surfaces (60), where the two connector surfaces (60) of each pair of connector surfaces (60) are formed in parallel to each other, wherein the connector surfaces (60) of one of the two pairs of connector surfaces (60) on the first connector (41) are formed at an angle relative to the connector surfaces (60) of the other of the two pairs of connector surfaces (60) on the first connector (41), wherein the second connector (42) comprises a receiving part (50) having a cross-sectional shape relative to the coupling direction (Di), mating with a cross-sectional shape of the first connector (41), and configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces (60) of the first connector (41), wherein the receiving part (50) of the second connector (42) comprises a set of carrier surfaces (51) each one carrier surface (51) being configured to be adjacent to and facing a specific one of the connector surfaces (60) on the first connector (41), when the first connector (41) and the second connector (42) are connected to each other, wherein a set of functional surfaces (100) is formed on at least a subset of the carrier surfaces (51) of the receiving part (50) of the second connector (42); wherein each functional surface (100) is formed as a top surface of an island (101) and elevated above the carrier surface (51), and wherein, at least one of the functional surfaces (100) is a pressure surface (200), wherein the pressure surface (200) is configured to provide a deformation of a connector surface (60) of the first connector (41).

Description

MODULAR TOY CONSTRUCTION SYSTEM CONNECTORS
The present invention relates to a connector for connecting items, such as elements or construction elements of a modular toy construction system.
More specifically, the invention relates to a modular toy construction system comprising a first construction element and a second construction element, the first construction element comprising a first connector, and the second construction element comprising a second connector: The first and second connectors are configured for connecting the first and second construction elements to each other.
The first connector comprises at least two pairs of connector surfaces, where the two connector surfaces of each pair of connector surfaces are formed such that they are acing away from each other on the first connector, and the two pairs of connector surfaces on the first connector are formed in an angle relative to each other. The second connector comprises a receiving part having a cross sectional shape mating with a cross-sectional shape of the first connector, and is configured for receiving and connecting to the first connector in a pressure fit (press fit connection) with the connector surfaces of the first connector. In such modular toy construction systems, at least the first connector is made of plastic/a polymer material, but often also the second connector.
Background of the invention
Connectors for modular toy construction systems are known in the art. These may take the shape of for example tube connectors or C-shaped/C-snap connectors, cross-shaped connectors and other types of connectors.
In cross-shaped connectors, one construction element has an elongate connector having a cross-shaped cross-sectional shape. Another construction element may have a corresponding receiving part in the form of a recipient space having a likewise cross-shaped cross-sectional shape, where the walls of the cross-shaped recipient space are configured to press on the cross shaped elongate connector of the first construction element, such that a press-fit/pressure fit is provided.
For example, such exemplary prior art tube cross-shaped connectors may be made in a polymer material. Such a polymer material may be ABS plastic. Such connectors, and/or the construction elements on which they are formed may for example be formed in an injection molding process, or alternatively in an additive manufacturing process.
Examples of modular toy construction systems and connectors therefore are know from e.g. US2003082986A1, W02010145660A1 and US2013252504A1.
DE2549185A1 discloses an example of toy sets having cross-shaped connectors.
It has shown, that in the prior connections, the function and quality of the connections between the various connector types of connectors is very sensitive to the type of material used for making the connection, and to the dimensions, such as material elasticity, material thickness, the overlap and friction properties of the construction elements of which they form part, etc., and that this induces a demand for extreme tolerances in making of the connectors for the modular toy construction systems.
In particular, the prior art connectors need to be made with a very small overlap. There is thus a need for connectors for modular toy construction systems, which lower the requirements on the tolerances in production of the construction element with connectors.
Thus, in order to produce a constant quality, for example the clutch power, of the connection between the two complementary connector parts of the connection, for each new construction element (e.g. block) design, a specifically dimensioned connector needs to be designed. Designing connections for hundreds or thousands of types of elements is time consuming and costly. Further, the invention provides a modular solution, where the quality of connections may be achieved for thousands of types of elements. Summary of the invention
It is therefore an object of the invention to provide connectors, which can more easily be adapted to be formed in various plastics, and for variously shaped and dimensioned construction elements of modular construction systems.
The objects of the invention are achieved by a modular toy construction system comprising a first construction element and a second construction element, the first construction element comprising a first connector and the second construction element comprising a second connector, the first and second connectors being configured for connecting the first and second construction elements to each other in a coupling direction, wherein the first connector comprises at least two pairs of connector surfaces, where the two connector surfaces of each pair of connector surfaces are formed in parallel to each other, wherein the connector surfaces of one of the two pairs of connector surfaces on the first connector are formed at an angle relative to the connector surfaces of the other of the two pairs of connector surfaces on the first connector, wherein the second connector comprises a receiving part having a cross- sectional shape relative to the coupling direction mating with a cross-sectional shape of the first connector, and configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces of the first connector, wherein the receiving part of the second connector comprises a set of carrier surfaces each one carrier surface being configured to be adjacent to and facing a specific one of the connector surfaces on the first connector, when the first connector and the second connector are connected to each other, wherein a set of functional surfaces is formed on at least a subset of the carrier surfaces of the receiving part of the second connector, wherein each functional surface is formed as a top surface of an island and elevated above the carrier surface, and wherein, at least one of the functional surfaces is a pressure surface, wherein the pressure surface is configured to provide a deformation of a connector surface of the first connector. The pressure surface provided on an island allows to control the interference or pressure fit between the first connector and the second connector more precisely, and to create a larger and more well defined pressure, and/or a larger and more well defined overlap between the first connector and the second connector. Further, the friction in the connection may be precisely controlled, whereby the clutch force or holding force of the connection may be designed constant for all connection types. This also allows producing new second connectors on new second construction elements, which are backwards compatible with existing first construction elements. Thereby, a new type of second connectors may be designed for new and old construction elements, which are connectable to the entire host of existing first connectors. Further, the new type of second connector may be designed more rapidly and simply for each new construction element, and for existing type construction elements which has a larger and more well defined pressure, and/or a larger and more well defined overlap. The possibility of increasing the and provide a more well defined pressure, and/or a larger and more well defined overlap, and the better controlled friction, results in an easy way of obtaining a constant clutch force (clutch feeling), for multiple types of construction elements. Further, the new connector type allows for reduced tolerances in production, making production in e.g. an injection molding process less costly, and reduces time in switching between molding different construction elements.
In an embodiment, the pressure surface is configured to provide a local deformation of a connector surface of the first connector.
By local deformation of a connector surface is meant a deformation which only occurs in the immediate vicinity of the location, where the pressure surface on the island contacts and presses on and/or into the connector surface.
Local deformation may provide an interference or pressure fit without any substantial deformation of the rest - or major part - of the connector surface of the first connector. Local deformation may further provide an interference or pressure fit without any substantial deformation of the carrier surface of the second connector. In an embodiment, when the first connector and the second connector are coupled to each other, no pressure is provided by the first connector or the second connector on the opposite of the two, except for at the at least one pressure surface.
In a further embodiment of any of the previously mentioned embodiments, the receiving part comprises a pair of pressure surfaces, arranged to provide pressure on respective connector surfaces of the first connector, when the first and second connectors are connected to each other, the pressure being applied in opposite directions.
In a further embodiment of any of the previously mentioned embodiments, when the first and second connectors have been connected, the one or more connector surfaces of the first connector contacts the second connector at the functional surfaces only.
In a further embodiment of any of the previously mentioned embodiments, the first connector fits in the second connector with at least a clearance everywhere between the first connector and the second connector, preferably with a small clearance, except where a pressure surface on an island is present to provide a pressure providing a deformation in the corresponding connector surface of the first connector.
In a further embodiment of any of the previously mentioned embodiments, the island is a protrusion extending at least from the carrier surface of the receiving part of the second connector.
In a further embodiment of any of the previously mentioned embodiments, the second connector correspondingly comprises two pairs of carrier surfaces, where the two carrier surfaces of each pair of carrier surfaces are formed in parallel to each other, and the carrier surfaces of one of the two pairs of carrier surfaces on the second connector are formed at an angle relative to the carrier surfaces of the other of the two pairs of carrier surfaces on the second connector. In a further embodiment of any of the previously mentioned embodiments, the functional surfaces of the set of functional surfaces are arranged in pairs of functional surfaces, wherein one functional surface of each pair of functional surfaces is formed on a first carrier surface, wherein the other functional surface of the same pair of functional surfaces (is formed on a second carrier surface, and wherein the first carrier surface and the second carrier surface are arranged in parallel to each other, wherein the first carrier surface and the second carrier surface are arranged on opposite sides of the receiving part in a direction perpendicular to the coupling direction, and wherein the one of the two functional surfaces of a pair of functional surfaces is arranged oppositely to the other of the same pair of functional surfaces in a direction perpendicular to the coupling direction.
In an embodiment thereof, apart from the translational freedom in the coupling direction, for each degree of rotational and translation freedom that the connection between the first connector and the second connector is configured to lock, one pair of functional surfaces is provided on a pair of parallelly arranged carrier surfaces of the receiving part of the second connector.
In a further embodiment, at least five pairs of functional surfaces are distributed on the carrier surfaces of the receiving part of the second connector.
In a further embodiment, the connector surfaces of one of the two pairs of connector surfaces on the first connector are formed orthogonally relative to the connector surfaces of the other of the two pairs of connector surfaces on the first connector, and the carrier surfaces of one of the two pairs of carrier surfaces on the second connector are formed orthogonally relative to the carrier surfaces of the other of the two pairs of carrier surfaces on the second connector.
In a further embodiment, the receiving part of the second connector has a rectangular cross-section in a plane perpendicular to the coupling direction, and two pairs of parallel carrier surfaces and wherein the carrier surface of the one pair of carrier surface are arranged perpendicular to the carrier surface of the other pair of carrier surface.
In these cases, the corresponding first connector comprises a mating rectangular cross-sectional shape in a direction perpendicular to the coupling direction.
In a further embodiment, where the receiving part of the second connector has a rectangular cross-section, two pairs of functional surfaces are formed in line with each other along the coupling direction on one of the two pairs of carrier surfaces, and two pairs of functional surfaces are formed in line with each other along the coupling direction on the other of the two pairs of carrier surfaces.
In a further embodiment, where the receiving part of the second connector has a rectangular cross-section, a further pair of functional surfaces is arranged on one of the two pairs of carrier surfaces, and in line with one other pair of functional surfaces in a direction perpendicular to the coupling direction.
In a further embodiment, where the receiving part of the second connector has a rectangular cross-section, at least one pair of functional surfaces is a pair of pressure surfaces.
In such cases the other pairs of functional surfaces, are pairs of datum surfaces. Datum surfaces will be described further below.
In a further embodiment, alternatively to embodiments where the receiving part of the second connector has a rectangular cross-section, the second connector may have an L-shaped cross-sectional shape in a direction perpendicular to the coupling direction, and the carrier surface of the one pair of carrier surface are arranged perpendicular to the carrier surface of the other pair of carrier surface.
In these cases, the corresponding first connector comprises a mating L-shaped cross-sectional shape in a direction perpendicular to the coupling direction. In a further embodiment, where the receiving part of the second connector has an L- shaped, two pairs of functional surfaces are formed in line with each other along the coupling direction on one of the two pairs of carrier surfaces, and two pairs of functional surfaces are formed in line with each other along the coupling direction on the other of the two pairs of carrier surfaces.
In a further embodiment, where the receiving part of the second connector has an L- shaped, a further pair of functional surfaces may be arranged on one of the two pairs of carrier surfaces, and in line with one other pair of functional surfaces in a direction perpendicular to the coupling direction.
In a further embodiment, where the receiving part of the second connector has an L- shaped, at least one pair of functional surfaces is a pair of pressure surfaces.
In such cases the other pairs of functional surfaces, are pairs of datum surfaces. Datum surfaces will be described further below.
In a further embodiment, alternatively, the receiving part first connector has a crossshaped cross-sectional shape in a direction perpendicular to the coupling direction.
In these cases, the corresponding first connector comprises a mating cross-shaped cross-sectional shape in a direction perpendicular to the coupling direction.
In an embodiment thereof, the second connector has four pairs of parallelly arranged carrier surface opposed connector surfaces arranged on two intersecting arms.
In a further embodiment, where the receiving part of the second connector crossshaped cross-sectional shape, two pairs of functional surfaces are formed in line with each other along the coupling direction on one of the four pairs of carrier surfaces, and wherein two pairs of functional surfaces are formed in line with each other along the coupling direction on a another of the four pairs of carrier surfaces.
In a further embodiment, where the receiving part of the second connector crossshaped cross-sectional shape, a further pair of functional surfaces is arranged on a third of the four pairs of carrier surfaces
In a further embodiment, where the receiving part of the second connector crossshaped cross-sectional shape, at least one pair of functional surfaces is a pair of pressure surfaces
In such cases the other pairs of functional surfaces, are pairs of datum surfaces. Datum surfaces will be described further below.
In a further embodiment of any of the previous embodiments, the first connector is made of plastic/a polymer material. As the first connector may, in some embodiments, be formed integral with, and, in other embodiments, constitute the first toy construction element, the first toy construction element including the first connector may in some embodiments be made of a plastic/polymer material.
In a further embodiment of any of the previous embodiments, the second connector is made of plastic/a polymer material. As the second connector may, in some embodiments, be formed integral with, and, in other embodiments, constitute the second toy construction element, the second toy construction element including the second connector may in some embodiments be made of a plastic/polymer material.
In an embodiment thereof, the islands provided with the functional surfaces are formed integrally with the second connector.
In a further embodiment of any of the previous embodiments, when the first and second connectors are connected, a clearance between the first and second connectors completely surrounds each of the pressure surfaces. In a further embodiment of any of the previous embodiments, the functional surfaces which are not pressure surfaces, are datum surfaces.
Datum surface, are functional surfaces configured to mate with a connector surface of the first connector without applying a deformation in the connector surfaces of the first connector.
In an embodiment thereof, when the first and second connectors have been connected to each other, a clearance between the first and second connectors completely surrounds each of the datum surfaces.
In a further embodiment the datum surface is raised relative to a carrier surface, and the datum surface is configured to mate with a connector surface (60) of the first connector to achieve minimal clearance, or neither clearance nor deformation of the mating connector surface of the first connector.
In a further embodiment of any of the previously mentioned embodiments, each island comprising a functional surface, comprises two inlet surfaces arranged on opposite sides of the functional surface in the coupling direction, and adjacent to the functional surface, where each inlet surface is connected to the functional surface via a respective transition, and where at least one of the inlet surfaces is configured for, during the act of coupling the first connector to the second connector, guiding one of the one or more connector surfaces of the first connector onto the functional surface.
The inlet surface configuration prevents or at least reduces damage to the functional surface.
In an embodiment, at least the transition connecting the functional surface with the inlet surface, which is configured for guiding one of the connector surfaces of the first connector onto the functional surface, has a radius of curvature about an axis perpendicular to the coupling direction, where said radius of curvature of the transition is smaller than a corresponding radius of curvature of the functional surface.
It will be appreciated that in some embodiment both inlet surfaces may be configured for guiding a connector surfaces of the first connector onto the functional surface.
Preferably, both transitions has a radius of curvature about an axis perpendicular to the coupling direction, where said radius of curvature of the transition is smaller than a corresponding radius of curvature of the functional surface.
In a further embodiment, a distance between the transitions in the coupling direction is larger than the corresponding length of the transition connecting the functional surface with the inlet surface that is configured for guiding one of the connector surfaces of the first connector onto the functional surface
In a further embodiment, the transitions have substantially the same elevation above the carrier surface.
In a further embodiment, one or both transitions forms an edge. By this is meant that in real life connectors and toy construction elements, any “edge” will be provided as a (narrow) surface between the two surfaces meeting in the edge. Thus, such a real life edge will have or constitute a transition or transition surface as mentioned above.
In a further embodiment, a curvature of the inlet surface is different from a curvature of the pressure surface.
In a further embodiment, the island may further comprise a side surface formed adjacent to the pressure surface in a direction perpendicular to the coupling direction, and between the pressure surface and the carrier surface, wherein the side surface is connected to the pressure surface via a transition, and wherein the transition is tangential from the pressure surface to the side surface in the direction perpendicular to the coupling direction.
It will be appreciated that in some embodiments, a side surface as defined in the previous paragraph may be provided adjacent to the pressure surface on both sides of the pressure surface, in a direction perpendicular to the coupling direction.
In a further embodiment, the transition from the inlet surface into the functional surface is smooth. This applies at least the transition connecting the functional surface with the inlet surface that is configured for guiding one of the connector surfaces of the first connector onto the functional surface. However, in further embodiments, it may also apply the opposite inlet surface.
In a further embodiment, at least the inlet surface facing the coupling direction, is formed such that during the act of connecting the first and second connectors, the shear on the inlet surface provided by the first connector on the inlet surface is constant over the travel of the first connector on the inlet surface from an inlet of the inlet surface to the transition to the functional surface.
In a further embodiment, at least the inlet surface facing the coupling direction, is formed as a curved or segmented surface, and is shaped to obtain a substantially constant shear curve for the shear force on the inlet surface caused by the first connector, when coupling the first and second connectors.
In a further embodiment, at least the inlet surface formed facing the coupling direction is formed between a catch surface at an inlet to the inlet surface and the pressure surface, and wherein a transition from the catch surface to the inlet surface is smooth.
In a further embodiment, at least the inlet surface formed facing the coupling direction, is formed between the carrier surface and the functional surface, and a transition from the carrier surface to the inlet surface is smooth. In a further embodiment, at least the inlet surface formed facing the coupling direction is formed as ramp. In further embodiments, also the opposite inlet surface may be formed as a ramp.
In a further embodiment, the carrier surface of the receiving part of the second connector surrounds the functional surface.
In a further embodiment, the carrier surface of the receiving part of the second connector completely surrounds the functional surface.
In an embodiment of any one of the previously mentioned embodiments, the island is elongate in shape, and has a first main longitudinal extent, the first main longitudinal extent preferably being parallel with the coupling direction.
In an embodiment of any one of the previously mentioned embodiments, each of the islands comprising a pressure surface, is configured to deform to accommodate the pressure between the pressure surface and the corresponding connector surface of the first connector, without any substantial deformation of the rest of the second connector, and preferably without any substantial deformation of the first connector, when the first connector and the second first connector are coupled to each other.
In an embodiment of any one of the previously mentioned embodiments, the first connector has a consistent diameter or width along its length, and the receiving part of the second connector has a consistent diameter or width along its length
In an embodiment of any one of the previously mentioned embodiments, where the first connector comprises an end surface formed perpendicular to the coupling direction, and where the second connector comprises an end surface formed perpendicular to the coupling direction, and where, when the end surfaces of the first connector and the second connector abut, relative movement between the first connector and the second connector in the coupling direction, is prevented. In an embodiment of any one of the previously mentioned embodiments, the first connector is configured as a male part, and the second connector is configured as a female part, and the receiving part is a cavity configured for receiving first connector.
In an embodiment thereof, where the first connector comprises an end surface formed perpendicular to the coupling direction, and where the second connector comprises an end surface formed perpendicular to the coupling direction, and where, when the end surfaces of the first connector and the second connector abut, relative movement between the first connector and the second connector in the coupling direction, is prevented.
In an embodiment thereof, wherein the end carrier surface is provided with an island comprising a functional surface
Alternatively, to the where the relative movement between the first connector and the second connector in the coupling direction, is prevented by abutment between end surfaces, the receiving part of the second connector may extends completely through the second connector, and the first connector is insertable into receiving part of the second connector from two opposite coupling directions.
In alternative embodiments, the first connector is configured as a female part, where the one or more connector surfaces are configured to surround a cavity, and where the second connector is configured as a male part, and where the receiving part is configured for inserting into the cavity formed in the first connector.
By at least one pair of the functional surfaces being configured to press on the connector surfaces of the first connector (when connected), the holding force may be controlled by a suitable dimensioning of the pressure surfaces.
In an embodiment of any of the previously described embodiments each of the functional surfaces has a curvature, a length and a width, wherein the length and the width are non-zero. In an embodiment thereof, where the functional surface is a pressure surface, the curvature, the length, the width, and a height of the pressure surface is dimensioned to provide a predetermined pressure on the connector surfaces of the first connector at a predetermined location of the connector surface of the first connector.
In a further embodiment of any of the previously mentioned embodiments, the functional surface has a surface area with a size that is a smidgen surface area of the carrier surface.
In an embodiment thereof, the size of the functional surface is less than 20% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 10% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 5% of the size of the carrier surface. In an embodiment thereof, the size of the functional surface is less than 2% of the size of the carrier surface.
The division of the contact and pressure between the first and second connectors into discrete “islands” of datum and pressure surfaces allows for optimal material usage in order to obtain the desired strain/stiffness and friction of the press fit connection and increased interface robustness. This is with optimal dimensioning obtained over a wide range of plastics.
In the context of the present invention, the term “smoothly transitioning” or “transitioning smooth” or “smooth transition” should be understood such that the transition between two surfaces, for example the pressure surface and the inlet surface, has a well-defined tangent in all locations in a direction parallel to the coupling direction. The transition is tangential. This means that there are no separating edges between the surfaces.
It should be emphasized that the term "comprises/comprising/comprised of" when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. Brief description of the drawings
In the following, the invention will be described in greater detail with reference to embodiments shown by the enclosed figures. It should be emphasized that the embodiments shown are used for example purposes only and should not be used to limit the scope of the invention.
Fig. 1A, in a perspective view, shows a set of prior art modular construction elements of a modular construction system, the construction elements having complementary coupling means in the form of cylindrical connectors and recesses;
Fig 1 B shows the construction elements of Fig. 1A in an end view;
Fig. 1C, in a bottom view, shows a prior art construction element with recesses for receiving and coupling to the cylindrical connectors;
Fig. 1 D shows a section, A-A, through the set of construction elements of Fig. 1C;
Fig. 2A, in a perspective view, shows a prior art second toy construction element having a cross shaped second connector for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 12C;
Fig. 2B, in a perspective view, shows a prior art second toy construction element having a cross shaped second connector for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 12C;
Fig. 2C, in a perspective view shows a prior art cross-shaped first toy construction element, which is also a first connector;
Fig. 2D, in a principal sketch, shows a section through the cross-shaped first connector shown in Fig. 2C; Fig. 2E, in a principal sketch, shows a section through a first connector having an L shaped cross section;
Fig. 2F, in a principal sketch, shows a section through a first connector having a rectangular cross-section;
Fig. 2G, in a principal sketch, shows a section through a first connector having a generally rectangular cross-section, but where the sides are curved;
Fig. 3A, in a front view, shows a second toy construction element having a cross shaped second connector with functional surfaces according to the invention, the second connector being configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C;
Fig. 3B is a sectional view of the second construction element shown in Fig 3A, along A-A in Fig 3A;
Fig. 3C is a sectional view of the second construction element shown in Fig 3A, along B-B in Fig 3A;
Fig. 4A is a front view of an island with a functional surface according to some embodiments of the invention;
Fig. 4B, is a sectional side view of the island with the functional surface, shown in Fig. 4A; and
Fig. 4C is another sectional view of the island with the functional surface, shown in Fig. 4A, the section taken perpendicular to the section shown in Fig. 4B
Fig. 5A, in a front view, shows another second toy construction element having a cross shaped second connector with functional surfaces according to an embodiment of the invention, the second connector being configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C;
Fig. 5B is a sectional view of the second construction element shown in Fig 5A, along A-A in Fig 5A;
Fig. 5C is a sectional view of the second construction element shown in Fig 5A, along B-B in Fig 5A;
Fig. 6A, in a front view, shows yet another second toy construction element having a cross shaped second connector with functional surfaces according to the invention, the second connector being configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C;
Fig. 6B is a sectional view of the second construction element shown in Fig 6A, along A-A in Fig 6A;
Fig. 6C is a sectional view of the second construction element shown in Fig 6A, along B-B in Fig 6A;
Fig. 7A, in a front view, shows yet another second toy construction element having a cross shaped second connector with functional surfaces according to an embodiment of the invention, the second connector being configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C;
Fig. 7B is a sectional view of the second construction element shown in Fig 7A, along A-A in Fig 7A;
Fig. 7C is a sectional view of the second construction element shown in Fig 7A, along B-B in Fig 7A; Fig. 8 is a sectional side view of an island with a functional surface according to embodiments of the invention, and shown in a distorted form to show details of the functional surface, the inlet surfaces and transition there between.
Detailed description of the embodiments
Figs. 1A-D shows an example of prior art construction elements or construction elements of a modular construction system 10. Such construction elements of a modular construction system 10 are often formed in plastic, and typically in an injection moulding process. The plastic materials used in for such construction elements of a modular construction systems 10 typically has a certain strength and elasticity depending on the geometrical inertia and the local deformation zone, material thickness and form as well as other parameters.
Figs. 1A shows two essentially identical construction elements 2A, 2B in the shape of building blocks. Each of these construction elements 2A, 2B comprises a body part 3 with a top face 4 on which eight cylindrical connectors are configured. The cylindrical connectors could also be called coupling studs or coupling knobs, or simply knobs 901. The knobs 901 are formed on the construction elements 2A, 2B in a regular two dimensional lattice or grid. The knobs 901 comprises a body 905 having an outer cylindrical surface 910.
The body part 3 of the construction elements 2A, 2B comprises sidewalls 6A, 6B, 6C, and 6D. Each of the sidewalls 6A, 6B, 6C, and 6D are configured with a lowermost edge 7 that forms a resting surface for the construction elements 2A, 2B.
Construction elements 2A, 2B of the type shown in Fig. 1A-D further comprises a set of cylinders 911 extending downward from a lower surface 912 of a wall 913 connection all of the sidewalls 6A-D. Between the inner surfaces 916 of the sidewalls 6A-D and outer surfaces of the one or more cylinder 911 , a set of knob receiving openings 902 are formed. The knobs 901 and the knob receiving openings 902 are configured for cooperating to releasably attach to each other in an interference fit/pressure fit. They are examples of complimentary connectors 900.
Construction elements 2A, 2B of the type shown in Fig. 1 are connected to each other by the sidewalls 6A, 6B, 6C, and 6D on the uppermost construction element 2A being pressed outwards, when the sidewalls 6A, 6B, 6C, and 6D are pressed down on the coupling studs 901 on the lowermost construction element 2B, following which, the sidewalls 6A-D, and outer surfaces 914 of the cylinders 911 press against the cylindrical outer surfaces 910 of the coupling studs 901 on the lowermost construction element 2B.
Elongate ribs 915 extending outward from an inner surface 916 of the sidewalls 6A- D, and being formed from the lower surface 912 of the wall 913 all the way to the lower edge 7, may constitute the contact between the knob 901 and the sidewalls 6A-D.
The complimentary connectors 900, i.e. the knobs 901 , formed on the upper surface 4 of the construction elements 2A, 2B, and the knob receiving opening 902, formed between the sidewalls 6A, 6B, 6C, 6D and the cylinders 911 , are provide in a regular two dimensional lattice, such as shown in Figs. 1A-D. Such complimentary connectors 100, 101 , 102 forms the basis of a plurality of modular toy construction systems known in the art.
Such complimentary connectors 100 are also known to be connectable to another type of connectors, than the one shown in Fig. 1C.
For example, the knobs 910 may connect to a tube connector 20. Other types of cylindrical connectors 900, similar to for example knobs 901, are examples of a first connector 41, connectable to a second connector 42, to which functional surfaces 100, 200, 300 formed on islands according to the invention may be applied. This will be described below. It will be appreciated that construction elements as described above may further comprise first connectors 41 and/or second connectors 42 as described in the following, or that they may be connected to other first construction elements 11 or second construction element 12 comprising such first connectors 41 and/or second connectors 42.
Turning now to Figs. 2A-G, showing examples of prior art first and second connectors 41, 42 for use in a modular toy construction system 10. The modular toy construction system 10 comprises a first construction element 11 and a second construction element 12. The first construction element 11 comprises a first connector 41 , and the second construction element 12 comprises a second connector 42. The first construction element 11 and the second construction element 12 may be releasably connected to each other by attaching/connecting the first connector 41 to the second connector 41.
In general, a first connector 41 comprises at least two pairs of connector surfaces 60, where the two connector surfaces 60 of each pair of connector surface 60 are formed such that they are facing away from each other on the first connector 41.
Further, the two pairs of connector surfaces 60 on the first connector 41 are formed in an angle relative to each other, where the angle is non-zero. Typically, the two pairs of connector surfaces 60 on the first connector 41 are formed perpendicular to each other, as in the shown examples, but other angles may be used.
The two pairs of connector surfaces 60 are configured for preventing translation of the first connector 41 relative to the a second connector 42, when connected, in two of three dimensions. Therefore, correspondingly, the second connector 42 comprises a receiving part 50 having a cross-sectional shape, which is configured for mating with a cross-sectional shape of a corresponding first connector 41. The receiving part 50 of the second connector 42 is configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces 60 of the first connector 41. Fig. 2C, in a perspective view shows a prior art cross-shaped first connector 41 of a first toy construction element 11 , i.e. the first connector has a cross shaped, cross sectional shape. The first connector 41 - in this case - constitutes the entire first construction element 11 , in the sense that the first connector 41 in the example shown in Fig. 2C is a first construction element also. It will however be appreciated that a first construction element 41 having other shapes may be formed with a cross-shaped first connector 41 as shown, or shorter or longer than shown in the figure. Fig. 2D, in a principle sketch, shows a section through a cross-shaped first connector 41 as in in Fig. 2C. The cross-shaped first connector 41 is an elongate structure with eight connector surfaces 60, four arm end surfaces 61 , and two end surfaces 65. In (not shown) embodiments a similar first connector 41 having a cross-shaped cross sectional shape may extend from a first construction element. In this case the first connector 41 is an elongate structure with eight connector surfaces 60, four arms (or two intersecting arms, each of the two intersecting arms having two opposed end surfaces 61), and two end surfaces 65.
Fig. 2A, in a perspective view, shows a prior art second toy construction element 12 having a cross shaped second connector 42 for connecting to e.g. a cross-shaped first toy construction element 11 , for example as shown in Fig. 2C. The second connector 42 in Fig 2A has an opening in each end and a receiving part 50, in the form of a thorough-going space having a cross-shaped cross sectional shape, which space is configured for receiving a first construction element 11 as shown in Fig. 2C. It will be appreciated, that the second connector 42 in Fig 2A has an opening in each end. Therefore, a first connector 41 as shown in Fig. 2C may be inserted into and coupled to the second connector 42 from two directions, the two opposed coupling directions Dj indicated by arrows in Fig. 2A.
It will further be appreciated, that since the receiving part 50 extends through the second connector 42, a first connector 41 as shown in Fig. 2C may be translated relative to the second connector 42, not just during coupling of the first connector 41 , but also after the connection has been made. Fig. 2B, in a perspective view, shows another prior art second toy construction element 12, also having a cross shaped second connector 42 configured for connecting to e.g. the cross-shaped first toy construction element 11 as shown in Fig. 2C. The second connector 42, shown in Fig. 2B has a receiving part 50, in the form of a space having a cross-shaped cross sectional shape, which space has an opening in one end and an end wall (not shown in Fig. 2A). The end wall maybe formed as a part of tube 12’ arranged perpendicularly to the second connector 42, and forming another part of the second toy construction element 12.
As was the case for the second connector 42 shown in Fig. 2A, the second connector in Fig. 2B is configured for receiving a first construction element 11 as shown in Fig. 2C. Due to the end wall, a first connector 41 as shown in Fig. 2C may be only inserted into and coupled to the second connector 42 from one direction, the coupling direction D indicated by an arrow in Fig. 2B. To uncouple the first connector 41 and the second connector 42 from each other, the first connector may be pulled in a direction parallel to, but opposite, the coupling direction Dj.
It will further be appreciated, that due to the end wall forming a stop, a first connector 41 as shown in Fig. 2C, when inserted into the receiving part 50 of the second connector 42 of Fig. 2B may NOT be translated relative to the second connector 42, once it has been coupled/attached, since a translation of the first connector 41 in the direction opposite to the arrow Dj will disengage the first and second connectors 41 , 42.
The second connectors 42 shown in Figs. 2A-B have in common that they are both configured for forming a connection with a cross shaped first connector 41 for example as shown in Fig. 2C. They differ in that a first connector 41 inserted in the second connector shown in Fig 2A is not locked from translational movement in the coupling direction, Dj, because there is no end stop. A first connector 41 inserted into the second connector 42 shown in Fig. 2B may only be inserted to the bottom thereof as defined by a separating wall between the second connector 42 and the perpendicularly arranged tube 12’. It will be appreciated that in both of the second connectors 42 of Figs. 2A and 2B, any inserted first connector 41 is locked from rotation in all three rotational directions.
The type of first connector 11 shown in Figs 2C and 2D has a cross-shaped cross section (in a direction perpendicular to a longitudinal direction of the first connector 41 , which is parallel to the coupling direction Dj) formed as two crossed or intersecting arms as shown in e.g. Fig. 2D. The two arms, in the shown case, intersect at the middle of each arm. It will however be appreciated that a similar function may be obtained if the intersection is displaced from the middle of one or both arms (and the corresponding second connector is configured to match the resulting cross-sectional shape).
In the first connector 41 of Figs. 2C-D, each arm has two side surfaces and an arm end surface 61. The side surfaces are used as connector surfaces 60 in the sense described above, in that they may be used to make contact with surfaces of the second connector 42. Thus, at least two pairs of connector surfaces 60 may be formed on the first connector 41. Two pair of connector surfaces 60 are formed on each arm, one pair on each side of the intersection between the arms. The connector surfaces 60 of each pair faces away from each other. In the shown example, the connector surfaces 60 of any one pair are formed parallel to each other. The connector surfaces 60 of the pairs of connector surfaces 60 on one arm are formed perpendicularly to the connector surfaces 60 of the each pair on the intersecting arm. Thus, the first connector 41 in this case (Figs. 2C-D) has eight connector surfaces 60.
In principle, also the arm end surfaces 61 may be used for contacting surfaces of a corresponding second connector 42, but in many practical applications first and second connectors 41 , 42 are designed such that a gap or clearance is provided between the arm end surfaces 61 and corresponding surfaces of the second connector 42.
In the shown example, the two arms intersect in a right angle, why the pairs of connector surfaces 60 are also formed at right angles to each other as well. It will be appreciated that it is also possible to have first connectors 41 and corresponding second connectors, where the arms intersect in other angles, and where consequently the pairs of connector surfaces 60 are formed at other angles to each other.
The first and second connectors 41 , 42 illustrated in Figs. 2A-D are examples of a commonly used type of connectors to which the invention (se further below) may be applied. Figs. 2E-G show other examples of first connectors 41 , to which a new second connector of the invention may be applied (se further below). Figs. 2E-G show a cross-section through the three differently shaped first connectors 41. It will be appreciated that a corresponding second connector 42 (not shown), having a matching shape may be provided for each of the illustrated first connectors 41.
The first connector 41 (and the corresponding second connector 42) is not necessary cross-shaped.
The first connector 41 shown in Fig. 2E has two arms, which are also formed perpendicularly to each other. The two arms in this case intersect at an end of each arm. The two arms can be said to be formed in a L-shape (in cross-section). Thus, two pairs of connector surfaces 60 may be formed on the first connector 41. A pair of connector surfaces 60 on each of the two intersecting arms. In each pair, the connector surfaces 60 faces away from each other. In the shown example, in each pair, the connector surfaces 60 are formed parallel to each other. The two pairs of connector surfaces 60 are formed perpendicularly to each other, such that each connector surface 60 of a pair of connector surfaces 60 on one arm are perpendicular to the pair of connector surfaces 60 on the intersecting arm.
Both in the case of the first connector 41 of Figs. 2C-D and the first connector 41 of Fig. 2E, the two arms intersects in a right angle, i.e. the arms - and the connector surfaces 60 thereon - are perpendicular to each other. However, in principle, the two arms may intersects in another angle. Again, the two pairs of connector surfaces 60, angled to each other, are configured for preventing translation of the first connector 41 relative to the a second connector 42, when connected, in two of three dimensions. In the case of the L-shaped first connector shown in Fig. 2E, if the arms were formed in another angle relative to each other, the shape could be said to be a V-shape.
In any case, the arms of the L or V shaped first connector 41 need not be the same length.
Fig. 2F shows another example of a first connector 41. The first connector 41 shown in Fig. 2F has a rectangular cross-shape. Thus, two pairs of connector surfaces 60 may be formed om the first connector, each connector surface 60 of a pair facing away from each other. In the shown case each connector surface 60 of a pair are formed parallel to each other. Further the connector surfaces 60 of one pairs of connector surfaces 60 are formed perpendicularly to the connector surfaces 60 of the other pair of connector surfaces 60. In principle, the contact surfaces 60 of a pair may not be formed parallel to each other. In such cases the first connector would not have a rectangular cross section but have a trapezoidal cross-section including, in principle Isosceles Trapezium/lsosceles Trapezoid, trapezium/trapezoid, and Irregular quadrilateral (Trapezoid)/ trapezium cross-sectional shapes. Again, the two pairs of connector surfaces 60 are configured for preventing translation of the first connector 41 relative to the a second connector 42, when connected, in two of three dimensions.
As shown in Fig. 2G the connector surfaces 60 of the first connector 41 may not be planar, but for example form arched surfaces. In Fig. 2G this is shown in connection with a generally rectangular shaped first connector 41. However, it is clear that arched contact surfaces 60 may also be applied to the shapes described above in connection with Figs. 2A-F.
In the prior art, the second connectors generally have contact surfaces formed as mating surfaces to the connector surfaces 60 of the first connector 41 , such that the contact surfaces on the second connector 42 are shaped and sized to match the connector surfaces 60 of the first connector 41. For this to work, it requires very precise tolerances in the production process. It has shown, that the function and quality of the connections between cross-shaped rods/shaft and cross-shaped second connectors 42, as described above are very sensitive to the type of material used for the making the connection, and to the overlap dimensions such as well as the geometrical inertia of the second construction element 12 to which they form part, etc., and that this puts demands for extreme tolerances in the production of such cross shaped connectors.
It has shown, that improved connections between first and second connector 41 , 42 may be obtained according to the present invention, where further the production costs may be considerably reduced by a combination of first and second connector 41 , 42 pairs or combinations according to the present invention, which is described with reference to Figs. 3A-7C in the following.
As mentioned above, the present invention relates to a modular toy construction system 10 comprising a first construction element 11 and a second construction element 12, where the first construction element 11 comprises a first connector 41 , for example as described in connection with Figs. 2A-G, and where the second construction element 12 comprises a second connector 42, which is configured for releasably connecting to the first connector 41 in a press fit connection/pressure fit connection. Thus, the first and second connectors 41 , 42 are configured for connecting the first and second construction elements to each other in a coupling direction, Dj.
Thus, as described above in connection with Figs. 2A-G, a first connector for the invention may take any of the cross-sectional shapes described above. The first connector 41 in the general case comprises at least two pairs of connector surfaces 60, where the two connector surfaces 60 of each pair of connector surface 60 are formed such that they are facing away from each other on the first connector 41. Further, the first connector 41 is formed such that connector surfaces 60 of one pair of connector surfaces 60 forms an angle relative to at least one pair of the other pairs of connector surfaces 60. The second connector 42 comprises a receiving part 50 having a cross sectional shape mating with a cross-sectional shape of the first connector 41.
The receiving part 50 of the second connector 42 may further comprise a set of carrier surfaces 51. The receiving part 50 is configured such that, for each connector surface 60, one carrier surface 51 is adjacent to each of the connector surfaces 60 on the first connector 41 , when the first connector 41 and the second connector 42 are connected to each other. This could also be formulated such that for each connector surface 60 on the first connector 41, a carrier surface 51 is formed on receiving part 50 of the second connector, in such a way that the carrier surface 51 faces the corresponding connector surface 60. Thus, the number and location of carrier surfaces 51 matches the number and location of the connector surfaces 60.
Corresponding to the shape of the first connector 41 , the second connector 42, in the general form, comprises two pairs of carrier surfaces 51 , where the two carrier surfaces 51 of each pair of carrier surfaces 51 are formed in parallel to each other.
Further, the carrier surfaces of one of the two pairs of carrier surfaces on the second connector are formed at an angle relative to the carrier surfaces of the other of the two pairs of carrier surfaces on the second connector.
The receiving part 50 of the second connector 42 further comprises a set of functional surfaces 100, for example as shown in Figs 3A-C. The functional surfaces
100 are formed on at least a subset of the carrier surfaces 51 of the receiving part 50 of the second connector 42.
Each functional surface 100 is formed as a top surface of an island 101 , the island
101 being formed on a carrier surface 51 , such that the functional surface 100 is elevated above the carrier surface 51 , which is for example illustrated in Fig 4A-C.
The receiving part 50 of the second connector 42 may, in some embodiments, be configured such that, when the first and second connectors 41 , 42 are connected to each other, the one or more connector surfaces 60 of the first connector 41 contacts the second connector 42 at the functional surfaces 100 only. One embodiment of such a second connector 42 is shown in Figs. 3A-C.
Fig. 3A, in a front view, shows a second construction element 12 having a cross shaped second connector 42 formed therein, and with functional surfaces 100 according to the invention. Each functional surface 100 is formed on an island 101 lifting the functional surface above the carrier surface. The second connector 42 of Figs. 3A-C is configured for connecting to e.g. a cross-shaped first toy construction element as shown in Fig. 2C.
In Figs. 3A-C, the second construction element 12 for simplicity is formed as a simple cubical element. It will be appreciated that the second construction element 12 may take many other shapes and forms. For example, the second construction element 12 may be formed like the second construction element 12 shown in Fig. 2A, or as a building block as illustrated in Figs. 1A-D.
It will be appreciated that the second connector 42 shown in Figs. 3A-C is of the type shown in Fig. 2A, where the first connector 41 is allowed to translate after coupling. It will also be appreciated, that Fig. 3A-C may also be representative for a second type connector 42 as in Fig. 2B, where an end wall could be envisaged in one of the ends of the receiving part 50. Such a second connector 42 with an end wall 54 and an end carrier surface 55 is illustrated in Figs. 7A-C.
As shown in Fig. 3A, the second connector 42 may be equipped with a number of functional surfaces 100 formed in pairs across from each other. The functional surfaces 100 of a pair of functional surfaces can also be said to face each other. Each of the functional surfaces 100 is formed on an island 101, raised above a carrier surface 51 of the second connector 42.
In the general case, the functional surfaces are preferably formed in pairs of functional surfaces 100, 200, 300.
The one functional surface 100, 200, 300 of each pair of functional surfaces 100, 200, 300 is formed on a first carrier surface 51. The other functional surface 100, 200, 300 of the same pair of functional surfaces 100, 200, 300 is formed on a second carrier surface 51 .
The first carrier surface and the second carrier surface of the pair are arranged in parallel to each other.
Further, the first carrier surface and the second carrier surface are arranged on opposite sides of the receiving part in a direction perpendicular to the coupling direction, Dj.
In the embodiments shown, the carrier surfaces are formed on a female part, why the receiving part forms a cavity, where the carrier surfaces are formed around the cavity, and defines the cavity. In such embodiments the first carrier surface and the second carrier surface carrying a pair of functional surfaces 100, 200, 300, faces each other.
Further, one of the two functional surfaces 100, 200, 300 of a pair of functional surfaces 100, 200, 300 is arranged oppositely to the other of the same pair of functional surfaces 100, 200, 300 in a direction perpendicular to the coupling direction Dj.
The functional surfaces 100 may be of two types. Thus, a functional surface 100 may be either a pressure surface 200 or a datum surface 300. The features and function of pressure surfaces 200 and datum surfaces, 300 respectively, will be described in further detail in connection with Figs. 4A-C below.
As mentioned above, the receiving part 50 of the second connector 42 shown in Figs. 3A-C, has a cross shaped cross-sectional shape (in a direction perpendicular to a longitudinal direction of the receiving part 50 of the second connector 42, which is parallel to the coupling direction Dj (which is shown in Fig. 3B), and represented by the z- axis in Figs. 3A-C). Thus the receiving part 50 comprises two crossed or intersecting arms. The two arms, in the shown case, intersect at the middle of each arm. It will however be appreciated that a similar function may be obtained if the intersection is displaced from the middle of one or both arms (and the corresponding second connector is configured to match the resulting cross-sectional shape).
On the left hand side of Fig. 3A, a set of pressure surfaces 200 is formed. On the right hand side of Fig. 3A a pair of datum surfaces 300 is formed. On the top of Fig. 3A two pairs of datum surfaces 300 are formed. Each of the functional surfaces 100 (pressure surfaces 200 or datum surfaces 300) is configured as described below in connection with Figs. 4A-C.
Fig. 3B is a sectional view along A-A in Fig 3A, of the second construction element 12 in Fig 3A, and Fig. 3C is a sectional view of the second construction element 12 shown in Fig 3A, along B-B in Fig 3A. In these views it is further illustrated that in a coupling direction Dj of the first connector 41 , two pairs of functional surface 100 may be formed in line or in series one after the other. It will be appreciated that, in the sections through the second connector 42, only one of the two functional surfaces 100 of a pair of functional surfaces 100, 200, 300 are visible.
Thus, in Fig. 3B two pairs of pressure surfaces 200 on the left hand side of the figure can be seen, each pair being represented by one of the two pressure surfaces 200 of the pair of pressure surfaces 200, which can be seen in line with each other in the direction of the coupling direction Dj.
On the right hand side of Fig. 3B, there is one pair of datum surfaces 300, represented by one of the two datum surfaces 300 of the pair of datum surfaces 300.
In Fig. 3C two pairs of datum surfaces 300 in the upper part of the figure can be seen, each pair being represented by one of the two datum surfaces 300 of the pair of datum surfaces 300, which can be seen in line with each other in the direction of the coupling direction Dj.
Turning now to the Figs. 4A-C and Fig. 8, the functional surfaces 100 will be described in further detail. Fig. 15A and Fig. 16 also indicates a coupling direction, Di, in which the first connector 41 is to be inserted into the second connector 42, or in which the second connector 42 is inserted into first connector 41 for bringing the one or more functional surfaces 100 into contact with the one or more connector surfaces 60.
The second connector 42 comprises a receiving portion 50. The receiving portion 50 comprises a set of carrier surfaces 51. Some or all of the carrier comprises functional surfaces 100.
Such functional surfaces 100 forms part of a modular toy construction system 10 according to the invention, where they may replace the traditional contact surfaces on second connectors 42 of second construction elements for a modular toy construction system 10 according to the invention.
The receiving portion 50 of the second connector 42 may be a male part or a female part. In the shown embodiments, however, the receiving portion 50 of the second connector 42 is exemplified as a female part, the receiving portion 50 forming cavity configured for receiving a first connector 41 in the form of a male part into the cavity.
It will however be appreciated that the receiving portion 50 of the second connector 42 may be a male part, having the one or more functional surfaces provided on an outer surface, and where the first part 41 comprise a cavity configured for receiving the male second connector there in to.
The functional surfaces may be either pressure surfaces 200 or datum surfaces 300.
Pressure surfaces 200 are arranged and dimensioned on the second connector 42 in such a way that the pressure surface 50 will provide a pressure on a connector surface 60 of a connected first connector 41. Preferably, pressure surfaces 200 are arranged and dimensioned on the second connector 42, such that the pressure surface 200 will provide a local deformation of the connector surface 60 of a connected first connector 41. This deformation will only occur in the immediate vicinity of the pressure surface 200. Datum surfaces 300 are arranged on and dimensioned on the second connector 42 in such a way, that the datum surfaces 300 do not provide a pressure on the corresponding connector surface 60 of a connected first connector 41 (when connected), but only provide a snug fit, such that datum surfaces 300 may provide guide surfaces for locating the first connector correctly relative to the pressure surfaces 200.
It will be appreciated that the number of functional surfaces 100, and their type, pressure surfaces 200 and datum surfaces300 may vary according to the connector. However, there must be least two pairs of functional surfaces 100, 200, 300.
According to an aspect of the invention, the one or more connector surfaces 60 of the first connector 41 only contacts the second connector 42 at the two or more functional surfaces 100, when the first connector 41 and the second connector have been connected to each other.
In any case, each of the functional surfaces 100 are formed on an island 101 , such that the functional surface 100 is raised from - or extending away from - the carrier surface 51 of the receiving part 50, in the sense that the carrier surface 51 may extends 360° around the functional surface 200.
In any case, the functional surface is formed as a top surface, or the uppermost part of the island 101 , relative to the carrier surface 51 on which the island 101 is formed.
Where the functional surface 100 is a datum surface 300, when the first connector 41 and the second connector 42 are connected to each other, a gap or clearance between the first connector 41 and the second connector 42 (i.e. between the connector surface 60 and the carrier surface 51) will surround the island 101 on which the datum surface 300 is provided.
For pressure surfaces, in some embodiments, when the first connector 41 and the second connector 42 are connected to each other, a gap or clearance between the first connector 41 and the second connector 42 (i.e. between the connector surface 60 and the carrier surface 51) will surround the island 101 on which the pressure surface 200 is provided.
In other embodiments, depending on material properties of the first connector 41 and the second connector 42, and the shape and dimension of the island 101 and the pressure surface 200, when the first connector 41 and the second connector 42 are connected to each other, the deformation, such as a local deformation, of a portion of the first connector 41 will cause the connector surface 60 and the carrier surface 51 to be connected in an interference fit/pressure fit/press fit.
It will be appreciated from the previous paragraphs that the contact between the first and the second connectors 41, 42 is then only made at the functional surfaces 100, 200, 300. The carrier surface 51 is preferably not in contact with connector surface 60 the first connector 41.
In Figs. 4A-C, only a portion of the second connector 42 and the second construction element 12 is visible. However, it will be appreciated that the island 101 with a functional surface 100 may be part of a second connector 42 of a second construction element 12 of a modular toy construction system 10 as mentioned above.
The first and second connectors 41, 22 are configured for connecting the first and second construction elements 11, 12 to each other, in the sense that they are shaped and sized to be complimentary to each other.
In general, the first connector 41 may preferably be formed as an integral part of the first construction element 11.
However, in principle the first connector may alternatively be a separate component attachable to the first construction element 11 , preferably such that the first connector 21 is unreleasbly attached to the first construction element 11. In yet other embodiments, first connector 41 may be construed as a first construction element 41 in its own right. An example of the latter is shown in Fig, 2C.
In general, the second connector 42 may preferably be formed as an integral part of the second construction element.12. However, in principle the second connector 42 may alternatively be a separate component attachable to the second construction element 12, preferably such that the second connector 22 is unreleasbly attached to the second construction element 12.
Fig. 4A indicates a coupling direction, Di, in which a first connector 41 is to be inserted into the second connector 42, for bringing the two or more functional surfaces 100 into contact with the one or more connector surfaces 60 of a first connector 41.
Pressure surfaces 200 are preferably arranged on the receiving part 50 of the second connector 42, such that they are arranged in pairs. A pair of pressure surfaces 200 face each other.
Datum surfaces 300 are preferably also arranged on the receiving part 50 of the second connector 42, such that they are arranged in pairs. A pair of datum surfaces 300 face each other.
As mentioned, each pressure surfaces 200 is formed on an island 101, which is formed on a carrier surface 51 of the receiving part 50 of the second connector 42. The islands 101 are preferably formed as integral parts of the second connector 42.
As mentioned, each datum surfaces 300 is formed on an island 101 , which is formed on a carrier surface 51 of the receiving part 50 of the second connector 42. The islands 101 are preferably formed as integral parts of the second connector 42.
As mentioned above, the number of pressure surfaces 200 and the number of datum surfaces 300 may vary depending on the connector. The number of pressure surfaces 200, or more particularly the number of pressure connector 200 pairs, and the configuration of the pressure surface geometry defines the clutch force or drawing force of the connection between the first connector 41 and the second connector 42.
The arrangement of the datum surfaces 300, or more particularly the number of datum surface pairs, defines the stability of the connection to prevent misalignment and secures that the pressure surface 200 engage the connector surfaces 60 of the first connector 41 correctly.
In any case the islands 101 comprising a functional surface 100, may elevate the functional surface 1000 to a height, h, above the carrier surface 51 of the receiving part 50 of the second connector 50.
According to a further aspect of the invention, the shape of the islands 101 on which the functional surfaces 100 are located, are formed in such a way that the functional surface 100 (pressure surface 200 or datum surface 300) smoothly transcends into an inlet surface 400.
In some embodiments, the inlet surface 400 may smoothly transcend into the carrier surface 51.
In the context of the present invention, the term “smoothly transcending” or “smoothly transitioning” should be understood such that the transition between the functional surface 100 and the inlet surface 400, and/or between the inlet surface 400 and the carrier surface 51 , has a well-defined tangent in all points. The transition is tangential. This means that there are no separating edges between the surfaces.
The inlet surface 400 forms an angle to the functional surface 100. The inlet surface 400 serves to guide the first connector 41 towards the functional surface 100, with minimum introduced material strain, during the attachment of the first and second connectors 41, 42, such that the functional surface 100 is not damaged during repeated attachments and detachments. This may be provided by curving the inlet surface. Thus, the height, hi, of the inlet surface (above the carrier surface 51) in the coupling direction towards the functional surface 100 preferably forms a curve.
In preferred embodiments, the inlet surface 400 is formed such that when connecting the first and second connectors 41, 42, the shear on the inlet surface 400, provided by first connector 41 on the inlet surface 400 is constant over the travel of the first connector 41 on the inlet surface 400 from the inlet of the inlet surface 400 to the transition to the functional surface 100.
This may be provided by curving the inlet surface 400 such that the force induced by first connector on the inlet surface is kept constant in the coupling direction for connecting the first connector 41 to the receiving part 50 of the second connector 42 towards the functional surface 100.
Thus, the inlet surface 400 is inclined relative to the coupling direction, Di, where an angle of inclination varies along the coupling direction, Di. In one embodiment, the inclination angle initially gradually increases along the coupling direction towards the functional surface 100, and subsequently gradually decreases along the coupling direction, Di, approaching the functional surface 100.
Preferably, the angle of the inlet surface relative to a plane defined in the coupling direction varies continuously from the end of the inlet surface opposite to the pressure surface in the coupling direction to the pressure surface.
The curve may be defined by the following formula
Figure imgf000039_0001
where:
• x and y is the coordinates of the curve, where (0,0) is at the surface of the undercut, i.e. at the carrier surface 51,
SUBSTITUTE SHEET (RULE 26) • a is the end angle of the curve in radians,
• h is the height of the curve, i.e. the elevation or height of the inlet surface 400 over the carrier surface, where it transcends into the functional surface 100, and
• the curve ends at (h,y(h)).
The island 101 with a functional surface 100 is shown in section in Figs. 4B and Fig.16. In Fig. 16 the island 101 is shown in a view in order to show the transitions 600 between the inlet surfaces 400, 401 , 402 and the functional surface 100 in more detail. Thus, in Fig. 16 the inclination of the inlet surface 400, 401 , 402 appear steeper than they would in real islands. Further the length and height proportions are not representative.
At least the transition 600 connecting the functional surface 100 with the inlet surface 400 that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100 has a radius of curvature, RT, about an axis perpendicular to the coupling direction Di. The functional surface 100 may further has radius of curvature, Rp. In embodiments, where the functional surface 100 is planar, the radius of curvature, RP of the functional surface 100 is infinite, «, but in other embodiments, the functional surface 100 may be curved thus having a finite radius of curvature, RP. In any case the radius of curvature, RT, of the transition 600 is smaller than a corresponding radius of curvature, RP, of the functional surface 100. As shown in Fig. 16, preferably both transitions 600 has a radius of curvature, RT. The radius of curvature, RT, of the two transitions 600 need not be the same.
The functional surface 100 in any case has a length, L3, defined in a direction parallel to the coupling direction, Dj. The length, L3 of the functional surface 100 may be defined between the transitions 600 to each of the inlet surfaces 400. The distance, L3, of the functional surface 100, between the transitions 600 in the coupling direction Dj is larger than the corresponding length of each of the transitions 600, and at least larger than the corresponding length of the transition 600 connecting the functional surface 100 with the inlet surface 400 that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100.
Preferably, the height, h, or elevation above the carrier surface 51 , of the transitions 600 at either side of the functional surface 100 is substantially the same.
The transitions 600 may form an edge. By this is meant that in real life connectors and toy construction elements, any “edge” will be provided as a (narrow) surface between the two surfaces meeting in the edge. Thus, such a “real life” edge will have or constitute a transition 600 or transition surface as mentioned above.
As may be appreciated from Fig. 4B and 16, the inlet surfaces 400 preferably forms an angle relative to the functional surface 100, i.e. they are inclined relative to the functional surface 100, such that the inlet surfaces 400 may form ramps leading onto the functional surface 100.
As shown, in e.g. Fig. 4A, the island 100 may further comprise a side surface 700 formed adjacent to the pressure surface in a direction perpendicular to the coupling direction, and between the functional surface 100 and the carrier surface 51. Preferably, the side surface 700 is connected to the functional surface 100 via a transition. Preferably, this transition between the functional surface 100 and the side surface 700 is smooth. Preferably, the transition between the functional surface 100 and the side surface 700 is tangential from the functional surface 100 to the side surface 700 in the direction perpendicular to the coupling direction.
As shown in e.g. Fig. 4A, in some embodiments, a side surface 700 as described may be provided adjacent to the functional surface 7000 on both sides of the functional surface 100, in a direction perpendicular to the coupling direction Dj.
The configuration of the inlet surfaces 400 prevents or at least reduces damage to the functional surface 100 formed on the island 101. Thus, the inlet surface 400 serves to guide the first connector 41 towards the functional surface 100, with minimum introduced material strain, during the attachment of the first and second connectors 41, 42, such that the functional surface 100 is not damaged during repeated attachments and detachments.
Therefore, at least the inlet surface 400, 401 facing the coupling direction, is formed such that during the act of connecting the first and second connectors 41 , 42, the shear on the inlet surface 400, 410 provided by the first connector 41 on the inlet surface 400, 401 is constant over the travel of the first connector 41 on the inlet surface 400, 401 from an inlet 405 of the inlet surface 400, 401 to the transition 600 to the functional surface 100.
The inlet surface 400, 401 facing the coupling direction Dj is the inlet surface that is configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100. However, in further embodiments, the feature of constant shear may also apply the opposite inlet surface 400, 402, especially if this inlet surface is also configured for guiding one of the connector surfaces 60 of the first connector 41 onto the functional surface 100, but also if it is not.
At least the inlet surface 400, 401 facing the coupling direction, Dj, may be curved, e.g. as described above.
At least the inlet surface 400, 401 facing the coupling direction, Dj, may be formed as a segmented surface 400, 401 , 40T, 401 ”. Each segment 401 , 40T, 401 ” of the inlet surface 400, 401 may have it’s own inclination relative to the functional surface 100 and to the carrier surface 51 on which it is formed. A transition is formed between the segments 40T, 401”. Preferably such transition is smooth. Further, each of such segments 40T, 401” of the inlet surface 400, 401 may be curved (have a curvature and a radius of curvature).
In some embodiments, and as shown in Figs 4A-B, a catch surface 500 may be formed adjacent to the inlet surface 400 distally relative to the functional surface 100, and at an opening into the receiving part 50 of the second connector 42. The catch surface 500 serves to direct the first connector 41 towards the inlet surface 400 at the beginning of attaching a first connector 41 to a second connector 42. In embodiments, where a catch surface 500 is provided, a smooth transition of the inlet surface 400 into the catch surface 500 may be provided. In some embodiments (not shown) a portion of the carrier surface 51 is provided between the catch surface 500 and the inlet surface 400. In such cases, preferably, the e is made such that the inlet surface smoothly transcends into the carrier surface 51 which again smoothly transcends into the catch surface 500.
As shown in Fig 4-B, the islands 101 comprising a functional surface 100, may comprise an inlet surface 400 on two opposite sides of the functional surface 100 in the direction of coupling, Dj. In some embodiments, attachment or coupling may be desirable from two opposite ends of a second connector 42, for example in a second connector 42 as shown Fig. 3A-C. In such embodiments, an inlet surface 400 is preferably formed at both ends of the functional surface 100, which may serve to guide the first connector 41 towards the functional surface 100 during the attachment of the first and second connectors 41, 42, from two opposite directions. Thereby, the functional surface 100 is not damaged during repeated attachments and detachments. The second inlet surface 400, 402 may be formed as described above.
It will be understood that both an island 101 comprising a pressure surfaces 200 and an island 101 comprising a datum surface 300 may be formed as described above for functional surfaces in general. However, in some embodiment, the islands 101 having datum surfaces 300 may be formed such that the inlet surface (or inlet surfaces 400 are simple ramps having a uniform angle relative to the coupling direction Dj over the entire length of the inlet surface 400.
In any case, a further inlet surface 400 opposite to a first inlet surface seen in the direction of coupling, Di, forms an undercut 402. An undercut 402 allows to control the surface area of the functional surfaces 100, particularly pressure surfaces 200, together with the width, W3, of the functional surfaces 100, and serves the function of reducing or eliminating a spring-back effect of the connection between the first connector 41 and the second connector 42. Spring-back effect is understood as an angled reaction force pushing the interfaces apart. This phenomenon is very sensitive to geometrical misalignment and has a significant impact on experienced functionality and the maximum overlap of the pressure surfaces.
In some embodiments, the carrier surface 51 may extends completely, i.e. 360°, around the functional surface 100, such as the island 101 shown in the right hands side of Fig. 13B. In other embodiments, the carrier surface 51 may extends partly around the functional surface 100.
An intermediary raised surface 800, may formed between islands that are formed in line in the coupling direction. The intermediary raised surface 800 is elevated above the carrier surface 50 of the second connector 20. The intermediary raised surface 800 has a height above the carrier surface 50, which is smaller than the height of the functional surface 100, 200, 300 and larger than or equal to the smallest height of the neighbouring inlet surface 400, 402.
The connection between a first connector 41 and a second connector 42 having at least pressure surfaces 200 provided on islands 101 , or pressure surfaces 200 and datum surfaces 300, as described above, a allow an interference fit/press fit/pressure fit connection with a first connector 41, and provides a desired, predictable, and reliable functionality, measured in drawing force, with low sensitivity towards geometrical misalignment. The geometrical principles applied in the interface are generic and, therefore, not limited by geometrical sizes or material selection. Dimensioning for target functionality is more easily obtained than for the prior art pressure surfaces by faster dimensioning of functional surfaces 100, in particular pressure surfaces 200, ensuring a local deformation relative to the stiffness of the first and second connectors 41 , 42 depending on e.g. material properties and material thickness.
The desired functionality (measured in drawing force) is created by the press fit connection with overlap on the protruding pressure surfaces 200 (local deformation control), and through friction between the interfacing surfaces - protruding pressure surfaces 200 and the connector surfaces 60 of the first connector 41 , and the spring-back effect is eliminated with the implemented undercut 402. The datum surfaces 50 ensure desired positioning and grid compatibility without affecting functionality.
As mentioned above, the number of pressure surfaces 200 and the number of datum surfaces 300, or rather the number of pairs of either of the two kinds may vary depending on the connector. The number of pressure surfaces 200 and the geometry thereof may vary in order to secure a desired clutch force between the first and second connector 41 , 42, depending on the shape, hardness, dimensions, etc. of the first connector 41 and the second connector and the construction elements 11, 12 on which they are formed.
Further, also depending on the shape, hardness etc. of the first connector 41 and the second connector 41 , the shape of the functional surface 100 may be determined. Thus, in some embodiments the functional surfaces 100 may be convex, concave or planar, i.e. the radius R1 of the functional surface may vary. The functional surface may be rectangular, circular or oval.
The functional surfaces 100 extends in two dimensions, such that they have a length, L3, in the direction of coupling Di and a width, W3, perpendicular to the direction of coupling, Di as exemplified in e.g. Fig. 4A-B. The length L3 and the width W1 are non-zero values. It is noted, that the length L3 and width W3 of a functional surface 100 may be major and minor axes of an ellipse (not shown).
In any case, the length, L3, and the width, Wi,of the functional surfaces 100, and at least of the one or more pressure surfaces 200, are non-zero.
Further, the island 101, on which the functional surface 100 is formed, extends in two dimensions, such that they have a length, L0, in the coupling direction Dj and a width, W0, perpendicular to the coupling direction, Dj as exemplified in e.g. Fig. 4A- B. It is noted, that the length L0 and width W0 of an island may be major and minor axes of an ellipse(not shown). An island 101 having a functional surface 100 has a length L0 in the coupling direction Di for attaching a first connector 41 . The length, L0, is defined as the distance in the coupling direction Di between a first met inlet surface 400 (or from the associated catch surface 500, if present) across the inlet surface 400, the functional surface 100 and an opposite inlet surface 400 (undercut 402) and an associated catch surface 500, if present.
Preferably, the length Lo of an island having a functional surface 100 is smaller than the total length of the connection between the first connector 41 and the second connector 42, as defined by the length of the carrier surface 51 in the direction of coupling, Di. More preferably, the length, L0, of the island is smaller than half of the total length of the connection between the first connector 41 and the second connector 42. In some embodiments, the length, L0, of the island is smaller than one third of the total length of the connection between the first connector 41 and the second connector 42.
In any case, preferably, the length, Lo ot the island is preferably larger than one fifth of the total length of the connection between the first connector 41 and the second connector 42.
As mentioned, the functional surfaces 100 has a radius, R1 , a length L3 and a width W3. The radius, R1 , the length L3 and the width W3 are dimensioned to provide a predetermined pressure on the connector surfaces 60 of the first connector 41 at a predetermined location of the connector surface 60 of the first connector 41.
The inlet surface 400 may be a straight planar surface, or in not shown embodiments comprises a curved surface portion, at least in the direction of the coupling direction, Di.
Returning now to Fig. 3A-C, it will be appreciated that the functional surfaces 100 are arranged in pairs, where in a pair, one functional surface 100 is arranged on an island 101 on each of two mutually facing (opposed) carrier surfaces 51. In general, for each degree of rotational and translation freedom that the connection between a first connector 41 and a corresponding second connector 42 is determined to lock, a pair of functional surfaces 100, 200, 300 is provided on opposed carrier surfaces 51 of the receiving part 50 of the second connector 42.
Thus, for a second connector 42 for a modular toy construction system 10, such as the second connector 42 shown in Fig. 3A-C, at least five pairs of diametrically opposed functional surfaces 100, 200, 300 are distributed on the carrier surfaces 51 of the receiving part 50 of the second connector 42. Thereby, a first connector 41 coupled to the second connector 42 will be locked against rotation in all three dimensions relative to the second connector 42. Further, the first connector 41 will be locked from translational movement in two directions/dimensions (x and y directions/dimensions in the figure), while one translational direction is free (z- direction) in Figs. 3A-C. It will be appreciated that translation in the z-dimension parallel to the coupling direction, Di, may be locked by providing an end wall 54 in the second connector 42, as shown in Figs. 7A-C. The end wall 54 comprises an end carrier surface 55, facing - or forming part of - the receiving part 50, on which the end surface 65 of the first connector 41 may abut when the first connector 41 is coupled to the second connector 42 at the intended position.
In (not shown) embodiments, the end carrier surface 55 of the second connector 42 as shown in Figs. 7A-C 11, may further be provided with an island 101 comprising a functional surface 100. This will allow a more precise location of the first connector 41 when coupled to the second connector 42.
In principle and in order to increase the stability of the connection/coupling, the end carrier surface 55 of the second connector 42 may further be provided with more than one island 101 (each island 101 comprising a functional surface 100), such as a pair of islands 101 (each island 101 comprising a functional surface 100).
The above mentioned prevention from rotation between a first connector 41 and a second connector in one dimension (about an axis of a coordinate system) is provided in the following way: For at least a set of mutually opposing connector surfaces 60 of the first connector 41 , i.e. connector surfaces 60 facing away from each other (such that on an arm of the firs connector 41 in Fig. 2C), and which two mutually facing carrier surfaces 51 of the corresponding receiving part 50 of the second connector 42 are arranged to face, the mutually facing carrier surfaces 51 may be provided with two pairs of functional surfaces 100 arranged in series to each other in a direction parallel with the coupling direction (Di), as exemplified in e.g. Fig. 3B.
In Fig. 3B only one of the two mutually facing carrier surfaces 51 is seen. However, the mutually facing carrier surface 51 , which is provided with the other of the mutually facing functional surfaces 100, of the two pairs of functional surfaces 100, can be seen in the front view of Fig. 3A, on the left hand side arm, on the upper side of the arm (when oriented as in Fig. 3A). It will be appreciated that when such two pairs of functional surfaces 100 are arranged in linear extension of each other, a first connector inserted therein will abut on the four functional surfaces, and that this will prevent rotation in one dimension (in this example rotation around the y-axis is prevented).
As may be appreciated from Fig. 3C, a similar arrangement (two pairs of functional surfaces 100 in series in the direction parallel to the coupling direction Dj) may further be provided on a pair of mutually facing carrier surfaces 51 , which are arranged perpendicular to the mutually facing carrier surfaces 51 mentioned in the previous paragraph. Thereby, a first connector 41 coupled to the second connector of Figs. 3A-C, will be locked against, i.e. prevented from, rotation in a second dimension (in this example rotation around the x-axis is prevented).
Rotation in the third dimension, i.e. about the z-axis, which is here coinciding with the coupling direction Dj (and the longitudinal direction of an inserted first connector 41), may be prevented by adding one more pair of functional surfaces 100 on a pair of mutually facing carrier surfaces 51 in a direction perpendicular to the coupling direction Dj. In Fig. 3B, this is exemplified by the single functional surface 100 on the vertically oriented carrier surface on the right hand side of the figure. The other one functional surface 100 of this pair of functional surfaces 100 (or actually both of the surfaces) can be seen in section in Fig. 3A on the right arm, and (also in a (longitudinal) section) in Fig. 3C on the right hand side of the receiving part 50 of the second connector 42.
It will be appreciated that two pairs of functional surfaces 100 arranged in series in the direction parallel to the coupling direction Dj in this case would also work. However, only one additional pair of functional surfaces 100 is needed to secure the first and second connectors 41, 42 from rotation in the last of the three dimensions (here: about the z-axis), when rotation in the other dimensions have been prevented as described above.
It will also be appreciated that the configuration of 5 pairs of functional surfaces as shown in Figs. 3A-C is sufficient to prevent translation of a first connector 41 coupled to the second connector 42 in a direction along the x- axis and the y axis, i.e. in two dimensions.
It will also be appreciated, that if, in an application of the invention, it would be desirable to allow for example slight rotation about one of the x, y, or z axes, a pair of functional surfaces out of the five pairs could be omitted.
For example, omitting the single pair of functional surfaces 100 shown in the right hand side of Fig. 3B, or just one of the functional surfaces 100 of the pair, then a slight rotation about the z-axis could be obtained. This could for example be used in a toy construction set of the modular toy construction system 10, to imitate a key (partially) turning in a key hole. Likewise, omitting one pair of functional surfaces 100 of one of the pairs of functional surfaces arrange in series along the coupling direction (or just one of the functional surfaces 100 of the pair of surfaces.), would allow a slight rotation about the x-axis or y-axis in the figure. This could be for example be used in a toy construction set of the modular toy construction system 10, to imitate a gear stick in a car.
In the previous paragraphs, the principle of using a pair of functional surfaces to lock against movement between a first connector 41 and a second connector coupled thereto, in a translation direction or a rotation direction has been described in connection with Figs. 3A-C for connector pairs (of first and second connectors 41 , 42) having cross shaped cross sectional shape. However the same apply to all the pairs of first and second connectors 41, 42 described in connection with Figs. 2A-G, e.g. rectangular connectors, such as described in connection with Figs. 2F-G, and V and L shaped connectors, such as described in connection with Fig. 2E.
In any of the embodiments described above and below, the first connector 41 may be formed in a polymer material. Such a polymer material may be ABS plastic. However, many other types of polymers are conceivable. Forming the first connector in a polymer may allow to form the first connector 41 in e.g. an injection molding process, or for example in an additive manufacturing process, depending among other things on the material choice.
In any of the embodiments described above and below, the second connector (42) is formed in a polymer material. Such a polymer material may be ABS plastic. However, many other types of polymers are conceivable. Forming the second connector 42 in a polymer may allow to form the second connector 42 in e.g. an injection molding process, or for example in an additive manufacturing process, depending among other things on the material choice. Preferably, the islands 101 provided with the functional surfaces 100 are formed integrally with the second connector 42.
As also mentioned above, the functional surfaces 100, may of one of two types, pressure surfaces 200 and datum surfaces 300. Functional surfaces 100 of a pair of functional surfaces 100 are of the same type. Thus, a pair of functional surface 100 facing each other are either both pressure surfaces 200 or they are datum surfaces. 300.
In principle, all of the functional surfaces 100 of a second connector 42 of the invention may be datum surfaces 300. It is clear that, since datum surfaces do not press on the connector surfaces 60 of a first connector 41 (when coupled to the second connector) but is formed match snugly on opposed connector surfaces 60 of the first connector, such as to function only as positioning means, friction between a second connector 42 and a first connector 41 coupled thereto, would be very low, why the connection there between would be unstable. The first connector 41 could easily slip out of the second connector 42.
Therefore, in an embodiment of the modular toy construction system 10 according to the invention, the set of functional surfaces 100 comprises one pair of pressure surfaces 200.
In this context, a pair of pressure surfaces 200 is configured the same way as above, i.e. the two pressure surfaces 200 of the pair of pressure surfaces 200 are arranged on opposed carrier surfaces 51, i.e. two carrier surfaces 51 facing each other.
The two pressure surfaces 200 of the pair of pressure surfaces 200 are configured to provide a local deformation of a connector surface 60 of the first connector 41 when connected. This means that the distance between the two pressure surfaces 200 of the pair of pressure surfaces 200 is smaller than a distance between the two connector surfaces (facing away from each other) of the first connector, which the pressure surfaces engages.
As mentioned, in some embodiments, at least one pair functional surfaces are pressure surfaces 200. However, the number of pairs of pressure surfaces may vary, for example according to a desired holding force between the first connector 41 and the second connector. Exemplary embodiments hereof are described below.
The pairs of functional surfaces 100, which are not pressure surfaces 200 are datum surfaces 300.
In the exemplary embodiment, shown in Figs 3A-C, there are two pairs of pressure surfaces 200. The two pairs of pressure surfaces 200 are arranged in series relative to each other in a direction parallel with the coupling direction (Di), as exemplified in e.g. Fig. 3B, see the left side of Fig. 3B. One pair of the two pairs of pressure surfaces 200 are seen on the left arm seen in Fig. 3A. The other three pairs of functional surfaces 100, in the embodiment shown in Figs. 3A-C are datum surfaces 300. Thus, at least in the front view of Fig. 3A, it can be seen that the pressure surface (on the left arm) are elevated/raised further above the surrounding carrier surface 51 than the datum surface 300, which can be seen on the top arm and the right arm.
Figs 5A-C and Figs. 6A-C show other embodiments, where the number of pairs of pressure surfaces 200 and datum surfaces differ from that of the embodiment in Figs. 3A-C.
In the embodiment shown in Fig. 5A, which is otherwise identical to the embodiment of Figs. 3A-C, there are four pairs of pressure surfaces 200. Two pairs of the four pairs of pressure surfaces 200 are arranged, as in the embodiment in Fig. 3A. Further, two additional pairs of pressure surfaces 200 are provided in series relative to each other in a direction parallel with the coupling direction (Di), as seen e.g. in Fig. 5CB. As may be appreciated from Fig. 5C, a similar arrangement (two pairs of functional surfaces 100 in series in the direction parallel to the coupling direction Dj) of the two additional pairs of pressure surfaces 200 may be provided on a pair of mutually facing carrier surfaces 51 , which are arranged perpendicular to the mutually facing carrier surfaces 51 mentioned in relation to the first two pairs of pressure surfaces 200.
In, for example, the right arm of the receiving part 50 of the second connector in Fig. 5A, it can be seen that the last pair of functional surfaces 100 in this embodiment is a pair of datum surfaces 300.
In the embodiment shown in Fig. 6A, which is otherwise identical to the embodiment of Figs. 3A-C and Fig. 5A-C, all of the five pairs of functional surfaces are pressure surfaces 200.
As the pairs of pressure surfaces 200 are configured to provide pressure on the corresponding connector surfaces 60 of a first connector 41 (when connected), such as by a local deformation thereof, it is clear that increasing the number of pairs of pressure surfaces 200 relative to the number of datum surfaces 300, will increase the friction between the second connector 42 and a first connector coupled thereto, and thereby the holding force there between. In this way designing the relation between the number of pairs of datum surfaces 300 and the number of pairs of pressure surfaces 200, can be used to make connectors having a desired holding force between them.
The embodiment shown in Figs 7A-C has the same number of functional surface 100 as the embodiments of Figs. 3A-C, Figs. 5A-C and Figs. 6A-C, and the functional surfaces are located in the same locations. The embodiment shown in Figs 7A-C further has the same distribution of the pressure surfaces 200 and datum surfaces 300 as the embodiment shown in Figs. 5A-C. The embodiment differs from the embodiments of Figs. 3A-C, Figs. 5A-C and Figs. 6A-C in that the second connector 42 comprises an end stop, provided by the wall 54 as described previously. In further (not shown) embodiments, of a second connector 42, having such an end stop, the distribution of pairs of pressure surfaces may further vary. For example, such a second connector may have one pair of pressure surfaces 200 and four pairs of datum surfaces 300, such as the embodiment shown in Figs. 3A-C, or the second connector 42 may have four pairs of pressure surfaces 200 and zero pairs of datum surfaces 300, such as the embodiment shown in Figs. 6A-C.
Islands 101 configured to have a pressure surface 200 formed thereon could also be called a pressure island or pressure inducing island.
Islands 101 configured with a datum surface 300 thereon, could also be called a datum island or a positioning island.
It is to be noted that the figures and the above description have shown the example embodiments in a simple and schematic manner. Many of the specific mechanical details have not been shown since the person skilled in the art should be familiar with these details and they would just unnecessarily complicate this description. For example, the specific materials used and the specific injection moulding procedure have not been described in detail since it is maintained that the person skilled in the art would be able to find suitable materials and suitable processes to manufacture the container according to the current invention. List of parts
2A prior art (modular) construction element (brick type)
2B prior art (modular) construction element (brick type)
3 body part of construction element
4 top face of construction element
6A wall/side/sidewall of construction element (brick type)
6B wall/side/sidewall of construction element (brick type)
6C wall/side/sidewall of construction element (brick type)
6D wall/side/sidewall of construction element (brick type)
7 lower edge of construction element
10 (modular) toy construction system
11 first construction element/ first toy construction element of the modular toy construction system
12 second construction element/second toy construction element of the modular toy construction system
13 front surface of the second construction element41 first connector, connector provided on first construction element
41 first connector, connector provided on first construction element
42 second connector, connector provided on second construction element
50 receiving part configured for receiving and connecting to the first connector in a pressure fit with at least a portion of the one or more connector surfaces (30) the first connector
51 carrier surface
52 end surface of an arm of the first connector
54 end wall of second connector
55 end surface formed on end wall of the second connector
60 connector surface of first connector
61 arm end surface of an arm of the first connector
100 functional surface
101 island
200 pressure surface/force inducing surface/spring surface
300 datum surface/locator surface/guide surface
400 inlet surface 401 first inlet surface
40T portion of first inlet surface having first curvature or second angle relative to functional surface
401” portion of first inlet surface having second curvature or second angle relative to functional surface
402 second inlet surface/outlet surface/deforming surface/undercut
405 inlet of the inlet surface/inlet to the receiving part
500 catch surface
600 transition, transition between inlet surface and pressure surface/datum surface
700 side surface of island
800 intermediary raised surface, formed between islands that are formed in line in the coupling direction
900 complimentary connector/ cylindrical connector of first element
901 knob/first connector
902 knob receiving opening
904 end surface of body of cylindrical connector of first element
905 body of cylindrical connector of first element
907 internal space of body of cylindrical connector of first element
908 cylindrical depression formed into an end surface of the body
909 tubular wall of cylindrical connector
910 cylindrical outer surface of cylindrical connector of first element
911 cylinders extending downward from a lower surface of a wall connecting all of the sidewalls of a (brick type) construction element
912 lower surface of a wall connecting all of the sidewalls of a (brick type) construction element
913 wall connecting all of the sidewalls of a (brick type) construction element (formed perpendicular to the sidewalls of a (brick type) construction element)
915 rib formed on inner surface of the side walls of surface of body of cylindrical connector of first elementDi coupling direction
Di coupling direction
L0 length of island, total length of island
L1 total length of the cylindrical inner surface (carrier surface) of the tubular wall of the tube connector (second connector) L2 length of catch surface projected on a direction parallel to the coupling direction
L4 length of inlet surface facing away from the coupling direction in a tube connector L5 length of intermediary raised surface, formed below a pressure surface in the coupling direction of a second connector in the form of a tubular connector
L6 length of a rounded transition surface between the bottom surface of the tube connector 20 and the inner cylindrical surface
L7 length of inlet surface facing away from the coupling direction in a tube connector
WO width of island, total width of island
L3 length of functional surface
W2 width of datum surface in second connector in the form of a tube connector
W3 width of functional surface, with of pressure surface

Claims

Claims
1. A modular toy construction system (10) comprising a first construction element (11) and a second construction element (12), the first construction element (11) comprising a first connector (41) and the second construction element (12) comprising a second connector (42), the first and second connectors (41, 42) being configured for connecting the first and second construction elements (11 , 12) to each other in a coupling direction (Dj), wherein the first connector (41) comprises at least two pairs of connector surfaces (60), where the two connector surfaces (60) of each pair of connector surfaces (60) are formed in parallel to each other, wherein the connector surfaces (60) of one of the two pairs of connector surfaces (60) on the first connector (41) are formed at an angle relative to the connector surfaces (60) of the other of the two pairs of connector surfaces (60) on the first connector (41), wherein the second connector (42) comprises a receiving part (50) having a cross-sectional shape relative to the coupling direction (Dj), mating with a cross- sectional shape of the first connector (41), and configured for receiving and connecting to the first connector in a pressure fit with the connector surfaces (60) of the first connector (41), wherein the receiving part (50) of the second connector (42) comprises a set of carrier surfaces (51) each one carrier surface (51) being configured to be adjacent to and facing a specific one of the connector surfaces (60) on the first connector (41), when the first connector (41) and the second connector (42) are connected to each other, wherein a set of functional surfaces (100) is formed on at least a subset of the carrier surfaces (51) of the receiving part (50) of the second connector (42); wherein each functional surface (100) is formed as a top surface of an island (101) and elevated above the carrier surface (51), and wherein, at least one of the functional surfaces (100) is a pressure surface (200), wherein the pressure surface (200) is configured to provide a deformation of a connector surface (60) of the first connector (41).
2. The modular toy construction system (10) according to claim 1, wherein the deformation is a local deformation.
3 The modular toy construction system (10) according to claim 1 or 2, wherein, when the first connector (41) and the second connector (42) are coupled to each other, no pressure is provided by the first connector (41) or the second connector (42) on the opposite of the two, except for at the at least one pressure surface (200).
4. The modular toy construction system (10) according to any one of the claims 1-3, wherein the receiving part (50) comprises a pair of pressure surfaces (200), arranged to provide pressure on respective connector surfaces (60) of the first connector (41), when the first and second connectors (41 , 42) are connected to each other, the pressure being applied in opposite directions.
5. The modular toy construction system (10) according to any one of the preceding claims, wherein, when the first and second connectors (41 , 42) are connected, the one or more connector surfaces (60) of the first connector (41) contacts the second connector (42) at the functional surfaces (100) only.
6 The modular toy construction system (10) according to any one of the preceding claims, wherein the first connector (41) fits in the second connector (42) with at least a clearance everywhere between the first connector (41) and the second connector (42), preferably with a small clearance, except where a pressure surface (200) on an island (101) is present to provide a pressure providing a deformation in the corresponding connector surface (60) of the first connector (41).
7. The modular toy construction system (10) according to any one of the preceding claims, wherein the island (101) is a protrusion extending at least from the carrier surface (51) of the receiving part (50) of the second connector (42).
8. The modular toy construction system (10) according to any one of the preceding claims, wherein the second connector (42) correspondingly comprises two pairs of carrier surfaces (51), where the two carrier surfaces (51) of each pair of carrier surfaces (51) are formed in parallel to each other, and wherein the carrier surfaces (51) of one of the two pairs of carrier surfaces (51) on the second connector (42) are formed at an angle relative to the carrier surfaces (51) of the other of the two pairs of carrier surfaces (51) on the second connector (42).
9. The modular toy construction system (10) according to any one of the preceding claims, wherein the functional surfaces (100, 200, 300) of the set of functional surfaces (100, 200, 300) are arranged in pairs of functional surfaces (100, 200, 300), wherein one functional surface (100, 200, 300) of each pair of functional surfaces (100, 200, 300) is formed on a first carrier surface (51), wherein the other functional surface (100, 200, 300) of the same pair of functional surfaces (100, 200, 300) is formed on a second carrier surface (51), and wherein the first carrier surface and the second carrier surface are arranged in parallel to each other, wherein the first carrier surface and the second carrier surface are arranged on opposite sides of the receiving part (50) in a direction perpendicular to the coupling direction (Di), and wherein the one of the two functional surfaces (100, 200, 300) of a pair of functional surfaces (100, 200, 300) is arranged oppositely to the other of the same pair of functional surfaces (100, 200, 300) in a direction perpendicular to the coupling direction (Dj).
10. The modular toy construction system (10) according to claim 9, wherein, apart from the translational freedom in the coupling direction (Dj), for each degree of rotational and translation freedom that the connection between the first connector (41) and the second connector (42) is configured to lock, one pair of functional surfaces (100, 200, 300) is provided on a pair of parallelly arranged carrier surfaces (51) of the receiving part (50) of the second connector (42).
11. The modular toy construction system (10) according to claim 9 or 10, wherein at least five pairs of functional surfaces (100, 200, 300) are distributed on the carrier surfaces (51) of the receiving part (50) of the second connector (42).
12. The modular toy construction system (10) according to any one of the claims 9-
11, wherein the connector surfaces (60) of one of the two pairs of connector surfaces (60) on the first connector (41) are formed orthogonally relative to the connector surfaces (60) of the other of the two pairs of connector surfaces (60) on the first connector (41), and wherein the carrier surfaces (51) of one of the two pairs of carrier surfaces (51) on the second connector (42) are formed orthogonally relative to the carrier surfaces (51) of the other of the two pairs of carrier surfaces (51) on the second connector (42).
13. The modular toy construction system (10) according to any one of the claims, 9-
12, wherein the receiving part (50) of the second connector (42) has a rectangular cross-section in a plane perpendicular to the coupling direction (Di) , and two pairs of parallel carrier surfaces (51) and wherein the carrier surface (51) of the one pair of carrier surface (51) are arranged perpendicular to the carrier surface (51) of the other pair of carrier surface (51).
14. The modular toy construction system (10) according to claim 13, wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on one of the two pairs of carrier surfaces (51), and wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on the other of the two pairs of carrier surfaces (51).
15. The modular toy construction system (10) according to claim 14, wherein a further pair of functional surfaces (100, 200, 300) is arranged on one of the two pairs of carrier surfaces (51) and in line with one other pair of functional surfaces (100, 200, 300) in a direction perpendicular to the coupling direction (Dj).
16. The modular toy construction system (10) according to claim 15 or 16, wherein at least one pair of functional surfaces (100) is a pair of pressure surfaces (200).
17. The modular toy construction system (10) according to any one of the claims 9- 12, wherein the receiving part (50) of the second connector (42) has an L-shaped cross-sectional shape in a direction perpendicular to the coupling direction, (Di), and wherein the carrier surface (51) of the one pair of carrier surface (51) are arranged perpendicular to the carrier surface (51) of the other pair of carrier surface (51).
18. The modular toy construction system (10) according to claim 17, wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on one of the two pairs of carrier surfaces (51), and wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on the other of the two pairs of carrier surfaces (51).
19. The modular toy construction system (10) according to claim 18, wherein a further pair of functional surfaces (100, 200, 300) is arranged on one of the two pairs of carrier surfaces (51), and in line with one other pair of functional surfaces (100, 200, 300) in a direction perpendicular to the coupling direction (Dj).
20. The modular toy construction system (10) according to claim 18 or 19, wherein at least one pair of functional surfaces (100) is a pair of pressure surfaces (200).
21. The modular toy construction system (10) according to any one of the claims 9- 12, wherein the receiving part (50) of the second connector (42) has a cross-shaped cross-sectional shape in a direction perpendicular to the coupling direction (Dj).
22. The modular toy construction system (10) according to claim 21, wherein the second connector (42) has four pairs of parallelly arranged carrier surface (51) opposed connector surfaces (60) arranged on two intersecting arms.
23. The modular toy construction system (10) according to claim 22, wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on one of the four pairs of carrier surfaces (51), and wherein two pairs of functional surfaces (100, 200, 300) are formed in line with each other along the coupling direction (Dj) on a another of the four pairs of carrier surfaces (51).
24. The modular toy construction system (10) according to claim 23, wherein a further pair of functional surfaces (100, 200, 300) is arranged on a third of the four pairs of carrier surfaces (51).
25. The modular toy construction system (10) according to claim 23 or 24, wherein at least one pair of functional surfaces (100) is a pair of pressure surfaces (200).
26. The modular toy construction system (10) according to any one of the preceding claims, wherein the first connector (41) is made of plastic/a polymer material.
27. The modular toy construction system (10) according to anyone of the preceding claims, wherein the second connector (42) is made of plastic/a polymer material.
28. The modular toy construction system (10) according to claim 27, wherein the islands (101) provided with the functional surfaces (100) are formed integrally with the second connector (42).
29. The modular toy construction system (10) according to anyone of the preceding claims, wherein, when the first and second connectors (41 , 42) are connected, a clearance between the first and second connectors (41 , 42) completely surrounds each of the pressure surfaces (200).
30. The modular toy construction system (10) according to anyone of the preceding claims, wherein the functional surfaces (100) which are not pressure surfaces (200), are datum surfaces (300).
31. The modular toy construction system (10) according to claim 30, wherein datum surfaces (300) are configured to mate with a connector surfaces (60) of the first connector (41) without applying a pressure on the connector surfaces (60) of the first connector (41).
32. The modular toy construction system (10) according to claim 31 , wherein, when the first and second connectors (41 , 42) are connected, a clearance between the first and second connectors (41 , 42) completely surrounds each of the datum surfaces (300).
33. The modular toy construction system (10) according to any one of the claims SO-
32, wherein the datum surface (300) is raised relative to a carrier surface (50), and wherein the datum surface (300) is configured to mate with a connector surface (60) of the first connector (41) to achieve minimal clearance, or neither clearance nor deformation of the mating connector surface (60) of the first connector (41).
34. The modular toy construction system (10) according to anyone of the preceding claims, wherein each island (101) comprising a functional surface (100, 200, 300), comprises two inlet surfaces (400, 401 , 402) arranged on opposite sides of the functional surface (100, 200, 300) in the coupling direction (Di), and adjacent to the functional surface (100, 200, 300), wherein each inlet surface (400. 401 , 402) is connected to the functional surface (100, 200, 300) via a respective transition (600), and wherein at least one of the inlet surfaces (400, 401 , 402) is configured for, during the act of coupling the first connector (41) to the second connector (42), guiding one of the one or more connector surfaces (60) of the first connector (41) onto the functional surface (100, 200, 300).
35. The modular toy construction system (10) according to claim 34, wherein at least the transition (600) connecting the functional surface (100, 200, 300) with the inlet surface (400) that is configured for guiding one of the connector surfaces (60) of the first connector (41) onto the functional surface (100, 200, 300) has a radius of curvature (RT) about an axis perpendicular to the coupling direction (Di), wherein said radius of curvature (RT) of the transition (600) is smaller than a corresponding radius of curvature (RP) of the functional surface (100, 200, 300).
36. The modular toy construction system (10) according to claim 34 or 35, wherein a distance (L3) between the transitions (600) in the coupling direction (Dj) is larger than the corresponding length of the transition (600) connecting the functional surface (100, 200, 300) with the inlet surface (400) that is configured for guiding one of the connector surfaces (60) of the first connector (41) onto the functional surface (100, 200, 300).
37. The modular toy construction system (10) according to any one of the claims 34-
36, wherein the two transitions (600) have substantially the same elevation (h) above the carrier surface (51).
38. The modular toy construction system (10) according to any one of the claims 34-
37, wherein one or both transitions (600) forms an edge.
39. The modular toy construction system (10) according to any one of the claims 34-
38, wherein a curvature of the inlet surface (400) is different from a curvature of the functional surface (100, 200, 300).
40. The modular toy construction system (10) according to any one of the claims 34-
39, wherein the island (101) further comprises a side surface (700) formed adjacent to the functional surface (100, 200, 300) in a direction perpendicular to the coupling direction (Dj), and between the pressure surface (200) and the carrier surface (51), wherein the side surface (700) is connected to the functional surface (100, 200, 300) via a transition, and wherein the transition is tangential from the functional surface (100, 200, 300) to the side surface in the direction perpendicular to the coupling direction (Dj).
41. The modular toy construction system (10) according to any one of the claims 34-
40, wherein, at least the transition (600) from the inlet surface (400) to the functional surface (100, 200, 300), of the inlet surface (400, 401) that is configured for guiding one of the connector surfaces (60) of the first connector (41) onto functional surface (100, 200, 300), is smooth.
42. The modular toy construction system (10) according to any one of the claims 34-
41, wherein at least the inlet surface (400, 401) facing the coupling direction (Di), is formed such that during the act of connecting the first and second connectors (41 , 42), the shear on the inlet surface (400) provided by the first connector (41) on the inlet surface (400) is constant over the travel of the first connector (41) on the inlet surface (400) from an inlet (450) of the inlet surface (400) to the transition (600) to the functional surface (100, 200, 300).
43. The modular toy construction system (10) according to any one of the claims 34- 41 , wherein, at least the inlet surface (400, 401) facing the coupling direction (Di), is formed as a curved or segmented surface, and is shaped to obtain a substantially constant shear curve for the shear force on the inlet surface (400) caused by the first connector (41), when coupling the first and second connectors (41 , 42).
44. The modular toy construction system (10) according to any one of the claims 34-43, wherein at least the inlet surface (400, 401) formed facing the coupling direction (D) is formed between a catch surface (500) at an inlet (405) to the inlet surface (400, 401) and the pressure surface (200), and wherein a transition from the catch surface (500) to the inlet surface (400) is smooth.
45. The modular toy construction system (10) according to any one of the claims 34-44, wherein at least the inlet surface (400, 401) formed facing the coupling direction (D) is formed between the carrier surface (51) and the functional surface (100, 200, 300), and wherein a transition from the carrier surface (51) to the inlet surface (400) is smooth.
46. The modular toy construction system (10) according to any one of the claims 34-45, wherein at least the inlet surface (400, 401) formed facing the coupling direction (D) is formed as ramp.
47. The modular toy construction system (10) according to any one of the claims 34-46, wherein the carrier surface (51) of the receiving part (50) of the second connector (42) surrounds the pressure surface (200).
48. The modular toy construction system (10) according to any one of the preceding claims, wherein the island (101) is elongate in shape, and has a first main longitudinal extent, the first main longitudinal extent preferably being parallel with the coupling direction (Dj).
49. The modular toy construction system (10) according to any one of the preceding claims, wherein each of the islands (101) comprising a pressure surface (200), is configured to deform to accommodate the pressure between the pressure surface (200) and the corresponding connector surface (60) of the first connector (41), without any substantial deformation of the rest of the second connector (42), and preferably without any substantial deformation of the first connector (41), when the first connector (41) and the second first connector (41) are coupled to each other.
50. The modular toy construction system (10) according to any one of the preceding claims, wherein the first connector (41) has a consistent diameter or width along its length and wherein the receiving part (50) of the second connector (42) has a consistent diameter or width along its length.
51. The modular toy construction system (10) according to any one of the preceding claims, wherein the first connector (41) comprises an end surface (61) formed perpendicular to the coupling direction (Dj), and wherein the second connector (42) comprises an end surface (55) formed perpendicular to the coupling direction (Dj), and wherein, when the end surfaces of the first connector (41) and the second connector (42) abut, relative movement between the first connector (41) and the second connector (42) in the coupling direction, is prevented.
52. The modular toy construction system (10) according to any one of the preceding claims, wherein the first connector (41) is configured as a male part, and the second connector (42) is configured as a female part, and where the receiving part (50) is a cavity configured for receiving first connector (41).
53. The modular toy construction system (10) according to 52, wherein the first connector (41) comprises an end surface (61) formed perpendicular to the coupling direction (D), and wherein the second connector (42) comprises an end surface (55) formed perpendicular to the coupling direction (D), and wherein, when the end surfaces of the first connector (41) and the second connector (42) abut, relative movement between the first connector (41) and the second connector (42) in the coupling direction, is prevented by .
54. The modular toy construction system (10) according to claim 53, wherein the end carrier surface (55) is provided with an island (101) comprising a functional surface (100).
55. The modular toy construction system (10) according to claim 52, wherein the receiving part (50) of the second connector (42) extends completely through the second connector (42), wherein the first connector (41) is insertable into receiving part (50) of the second connector (42) from two opposite coupling directions (D).
56. The modular toy construction system (10) according to any one of the claims 1-51, wherein the first connector (41) is configured as a female part, where the one or more connector surfaces (60) are configured to surround a cavity, and wherein the second connector (42) is configured as a male part, and where the receiving part (50) is configured for inserting into the cavity formed in the first connector (41).
PCT/EP2023/087550 2022-12-22 2023-12-22 Modular toy construction system connectors WO2024133861A1 (en)

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PCT/EP2023/087538 WO2024133852A1 (en) 2022-12-22 2023-12-22 Tube connector for modular construction system

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US5527201A (en) * 1991-11-25 1996-06-18 Maddock; Paul T. Toy construction kit with interconnecting building pieces
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