U.S. patent application number 15/251953 was filed with the patent office on 2017-03-02 for posable toy linkage.
The applicant listed for this patent is Joseph Farco. Invention is credited to Joseph Farco.
Application Number | 20170056782 15/251953 |
Document ID | / |
Family ID | 58097470 |
Filed Date | 2017-03-02 |
United States Patent
Application |
20170056782 |
Kind Code |
A1 |
Farco; Joseph |
March 2, 2017 |
Posable Toy Linkage
Abstract
A linkage that couples a plurality of Lego blocks or Lego-like
blocks is posable and configured to provide a plurality of
three-dimensional orientations for the plurality of blocks it
interconnects.
Inventors: |
Farco; Joseph; (Deer Park,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Farco; Joseph |
Deer Park |
NY |
US |
|
|
Family ID: |
58097470 |
Appl. No.: |
15/251953 |
Filed: |
August 30, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62211822 |
Aug 30, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A63H 33/102 20130101;
A63H 33/103 20130101 |
International
Class: |
A63H 33/10 20060101
A63H033/10 |
Claims
1. A toy building block linkage made out of a metal wire and an
elastomer coating on the metal wire, the linkage having posability,
wherein the posability comprises a ratio of an area moment of
inertia of the elastomer coating to the area moment of inertia of
the wire being between about 1 and about 50.
2. The system of claim 1, wherein the posability further comprises
the area moment of inertia of the elastomer coating being less than
2.821.times.10.sup.-5 in.sup.4.
3. The system of claim 1, wherein the linkage is integrally coupled
to the at least one frictionally-interlocking building block.
4. The system of claim 2, wherein the linkage is integrally coupled
to the at least one frictionally-interlocking building block.
5. The system of claim 1, wherein the posabililty further comprises
a posability triangle comprising an angle .alpha., an angle .beta.
and an angle .gamma..
6. The system of claim 5, wherein angle .beta. or an angle .gamma.
is greater than 90 degrees measured clockwise from the at least one
wall.
7. The system of claim 6, wherein only angle .beta. is greater than
90 degrees measured clockwise from the at least one wall.
8. The system of claim 2, wherein the posabililty further comprises
a posability triangle comprising an angle .alpha., an angle .beta.
and an angle .gamma..
9. The system of claim 8, wherein angle .beta. or an angle .gamma.
is greater than 90 degrees measured clockwise from the at least one
wall.
10. The system of claim 9, wherein only angle .beta. is greater
than 90 degrees measured clockwise from the at least one wall.
11. The system of claim 3, wherein the posabililty further
comprises a posability triangle comprising an angle .alpha., an
angle .beta. and an angle .gamma..
12. The system of claim 11, wherein angle .beta. or an angle
.gamma. is greater than 90 degrees measured clockwise from the at
least one wall.
13. The system of claim 12, wherein only angle .beta. is greater
than 90 degrees measured clockwise from the at least one wall.
14. The system of claim 4, wherein the posabililty further
comprises a posability triangle comprising an angle .alpha., an
angle .beta. and an angle .gamma..
15. The system of claim 14, wherein angle .beta. or an angle
.gamma. is greater than 90 degrees measured clockwise from the at
least one wall.
16. The system of claim 15, wherein only angle .beta. is greater
than 90 degrees measured clockwise from the at least one wall.
17. A toy building block and connection kit, comprising: at least
one frictionally-interlocking building block comprising at least
one wall and at least one cylindrical stud extending upwardly from
the at least one wall; and a linkage having posability, wherein the
posability comprises an area moment of inertia between about
7.4.times.10.sup.-7 in.sup.4 and about 3.2.times.10.sup.-5
in.sup.4.
18. The toy building block and connection system of claim 17,
wherein the area moment of inertia is between about
4.9.times.10.sup.-6 in.sup.4 and about 3.2.times.10.sup.-5
in.sup.4.
19. The toy building block and connection system of claim 18,
wherein the posability further comprises a section modulus of
plasticity less than about 1.4000.
20. The toy building block and connection system of claim 19,
wherein the posability further comprises a section modulus of
plasticity less than about 0.58333.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 14/474,276, filed on Sep. 1, 2014 and claims
the benefit of U.S. Provisional Patent Application Ser. No.
62/211,822, priority to each of the aforementioned applications is
hereby claimed and the disclosures of each of which are
incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] Disclosed are embodiments of the invention that relate to,
among other things, building block linkage and joint systems and
methods.
BACKGROUND
[0003] Linkages for toy building blocks, such as those made by
LEGO.RTM., Duplo.RTM., Mega Bloks, Built to Rule, K'nex, Kre-O, and
others, provide limited degrees of movement and positioning in the
three dimensional plane for the blocks they connect.
[0004] Flexible plastic cables, string, plastic rods, and plastic
tubes have been used to connect building blocks, as illustrated and
described in U.S. Pat. Nos. 5,433,549, 5,733,168, 6,000,984,
6,213,839, 6,461,215, 6,676,474, 6,843,700, and PCT/DK1991/000373.
Other prior art systems are Lego.RTM. Technic Sets 5118, 7471,
8002, 8074, 8412, 8437, 8440, 8444, 8445, 8457, 8479, 8482, 8483,
8485, 8828, 8836, 8839, 8856, and 9748.
[0005] As shown in FIG. 1A, an end P1 is connected to a bendable
plastic rod P2 via neck P3. Front end P1, rod P2, and neck P3 are
shaped to be received in a complementary slot P11-P13 of the
receiver block P10. Thus, a plastic rod P2 with necks P3 and ends
P1 disposed on either terminus of the rod P2 is used to tether
blocks to which receiver block P10 may couple, provided the necks
P3 and ends P1 are capable of receipt in the receiver block slots
P11-P13. In an alternative arrangement shown by FIG. 1B, a receiver
block P10 is comprised of a jaw P5, a mouth P6, and a tooth P7 that
engages a recess/neck P3 in a plastic rod P2 received within block
P10. In this arrangement, the prior art receiver block P10 relies
on plastic-on-plastic coupling between tooth P7 and recess P3 to
maintain rod P2 in the block P10, e.g., a crimping connection.
[0006] All of these linkage systems suffer disadvantages in terms
of the reduction in strength from repeated use and/or exposure to
heat, weakness when loaded in a direction perpendicular to their
cross-section, and/or lack of ability to be bent in any number of
conformations while also substantially maintaining a conformation
in three-dimensional space, e.g., wilting or buckling in response
to loads.
SUMMARY OF THE INVENTION
[0007] A building block system for interconnecting Lego.RTM. and
non-Lego.RTM. like bricks together via use of at least a bendable
metal component that has posability with and without a coating
disposed on the metal surface.
[0008] By having posability, a linkage may have an unlimited range
of displacement in three-dimensional space and be able to hold its
conformation in loaded and/or unloaded configurations. Such a
linkage may serve as a universal joint for building blocks.
[0009] The posable linkage may be coupled to a building block using
one or more of the following: the building block apertures
themselves, a combination of the building block apertures and
intermediary components within the building block, and/or a socket
or adaptor disposed within the building block either alone or in
combination with other features of the building block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A-1B illustrate the prior art and have been
previously described.
[0011] FIG. 2 illustrates an exemplary embodiment of one form of
exemplary inventive building block linkage system.
[0012] FIGS. 3A-D illustrate exemplary embodiments of exemplary
building block linkages for an exemplary inventive building block
linkage system and assembly method.
[0013] FIGS. 4A-G illustrate other exemplary embodiments of other
forms of exemplary inventive building block linkage systems and
assembly methods.
[0014] FIG. 4H illustrates an exemplary socket loading technique
for exemplary inventive building block linkage systems.
[0015] FIGS. 5, 6A-B, and 7A-F illustrate other exemplary
embodiments of other forms of exemplary inventive building block
linkage systems and assembly methods.
[0016] FIGS. 8 and 8A-B illustrate views of an exemplary anchor
block for various forms of exemplary inventive building block
linkage systems and assembly methods.
[0017] FIGS. 9A and 9B illustrate still another exemplary
embodiment of other forms of exemplary inventive building block
linkage systems and assembly methods.
[0018] FIGS. 10A-C, 11A-C, 12A-C, and 13A-C illustrate other
exemplary embodiments of anchor blocks and linkages used in forms
of an exemplary inventive building block systems and assembly
methods.
[0019] FIGS. 14A-D illustrate other exemplary embodiments of
adaptors for exemplary blocks and linkages used in other forms of
an exemplary inventive building block systems and assembly
methods.
[0020] FIG. 15 illustrates an exemplary embodiment of an exemplary
inventive building block system.
[0021] FIGS. 16A-D illustrate exemplary embodiments of
linkages.
[0022] FIG. 17 illustrates an exemplary embodiment of an exemplary
method of manufacture of an exemplary posable linkage.
[0023] FIGS. 18A-D illustrate other exemplary embodiments of an
exemplary inventive building block system.
[0024] FIGS. 19A-D illustrate still further exemplary embodiments
of an exemplary inventive building block system.
[0025] In the drawings like characters of reference indicate
corresponding parts in the different figures. The drawing figures,
elements and other depictions should be understood as being
interchangeable and may be combined in any like manner in
accordance with the disclosures and objectives recited herein.
DETAILED DESCRIPTION
[0026] With respect to FIG. 2, an exemplary linkage 2 may be
configured to fit within an opening 5 of a receiving exemplary
building block 10 (hereinafter referred to as block or brick 10,
which may be a Lego-like brick). An exemplary brick 10 may be made
of plastic, rubber, or metal, but preferably PLA or Acrylonitrile
Butadiene Styrene (ABS) plastic. An exemplary brick 10 may be
prismatic, cubic, spherical, conical, pyramidal, or any other form
of polyhedron in shape. When assembled, the head 1 and tail 0 of an
exemplary linkage 2 may be located within a cavity 9 of exemplary
block 10. In an exemplary embodiment, head 1 of an exemplary
linkage 2 need not enter the exit 6 of exemplary block 10. The
opening 5 and exit 6 of an exemplary block 10 may also serve as
adaptors for connecting exemplary block 10 to other building
blocks. For example, in an exemplary Lego.RTM. block 10 opening 5
may be sized to fit within the exit 6 of another exemplary building
block (not shown). Conversely, an exit 6 of an exemplary Lego.RTM.
block 10 may be sized to fit about an opening 5 of another
exemplary building block. According to these embodiments, the
engagement between an exemplary linkage 2 and exemplary block 10
may be considered a joint 20.
[0027] In one embodiment, an exemplary linkage 2 is made of a metal
and is flexible yet posable. An example of posability may be that
an exemplary linkage 2 can be bent into any conformation, without
any limit on degrees of freedom of movement, and substantially
maintain that conformation in three-dimensional space. As another
example of posability, an exemplary linkage 2 may be configured to
dispose at least two blocks 10, which are adapted to receive an
exemplary linkage 2, in different positions in three-dimensional
space and substantially maintain those positions over time without
the need for any other movable parts but the linkage 2.
Accordingly, an exemplary linkage 2 may be the exclusive means of
positioning exemplary building blocks which it interconnects. As
such, an exemplary linkage 2 may allow exemplary building blocks to
be translated, rotated, and/or held in positions with respect to
one another in three-dimensional space. Further alternatively, an
exemplary linkage 2 may couple a plurality of different block
systems together, e.g., a Lego.RTM. block to a K'nex piece.
[0028] In another embodiment, an exemplary linkage 2 may have one
or more of the following exemplary characteristics: (i) a wire-like
shape; (ii) made out of one or more of the following and/or their
combinations and/or galvanized variants: aluminum, copper, iron, or
brass; (iii) dimensioned so that it can be received within an
opening 5 and/or an exit 6 of an exemplary block 10; (iv)
dimensioned so that it can be received within fabric, flexible
plastic, or elastomer tubing; (v) dimensioned so that its diameter
is within the range of diameters between those of opening 5 and
those of exit 6 of an exemplary block 10; (vi) a diameter of
approximately 0.123 inches to approximately 0.193 inches; (vii) be
approximately 5- to approximately 8-gauge wire; or (viii) be an
armature wire. In an exemplary embodiment, an exemplary linkage 2
is about 0.12574 inches in diameter and is made from a flexible
aluminum armature wire. While an exemplary linkage 2 may preferably
be circular in cross-section, any number of cross-sections of an
exemplary linkage 2 may be contemplated depending on the exemplary
brick with which it couples.
[0029] For example, an exemplary linkage 2 may be configured so
that it and/or its head 1 or tail 0 may friction-fit within an
exemplary block 10 opening 5, exit 6, and/or other such aperture as
described herein, provided the exemplary block 10 material creating
the cross-section of such opening 5, exit 6, and/or other such
aperture does not go beyond its modulus of resilience (e.g., the
cross-section may be the same as or smaller than the cross-section
of an exemplary linkage 2, head 1, and/or tail 0). Where multiple
cross-sections are involved, an average cross-section may be used
to determine the applicable modulus of resilience. An average
cross-section of an exemplary linkage 2 may be the cross-section at
one end of linkage 2 to the point on linkage 2 just before where
the cross-section remains substantially un-changed along the length
of linkage 2. An average cross-section may be utilized for
determining the average cross-section of an aperture in exemplary
block 10, e.g., measuring the cross-section from the opening 5 or
exit 6, whichever is closest to the cross-section of the aperture
surface most distal to the beginning measuring point whether it be
opening 5 or exit 6 as the case may be.
[0030] An exemplary linkage 2 may be included in and made out of
any other material or combination of materials that results in
properties equivalent to those achieved by structures with one or
more of the foregoing characteristics and posabilities. For
example, a metal wire may be included within an elastomer tube so
that the combination of the two, which together form an exemplary
linkage 2, may have the flexibility and posability of the
underlying metal wire (for example the illustrative embodiments and
related disclosures of FIGS. 16A-D). Those skilled in the material
arts may be able to identify other materials of which a single
exemplary linkage 2 can be made to achieve one or more of the
foregoing requirements of the metal linkage 2 embodiments, such as,
polymers and plastics, provided the final composition has
posability.
[0031] An exemplary linkage 2 may have a plurality of orientations
in three-dimensional space in which it may position blocks coupled
thereto. In the illustrative embodiment of FIG. 2, any number of
different points in three-dimensional space, identified by
Cartesian coordinates (x, y, z), may be found about the length of a
single exemplary linkage 2. For example, point "A" on an exemplary
linkage 2 has exemplary coordinates (0, 0, 0), meaning that this
portion of exemplary linkage 2 may serve as an origin position or
point of comparison. Point "B", which has coordinates (-1, 1, -1),
may suggest that this part of linkage 2 is located in a plane
behind and above Point "A" in three-dimensional space. Point "C",
which has coordinates (1.5, -0.5, 1), may suggest that this part of
an exemplary linkage 2 is in a plane ahead of and under point "A."
Thus, each of the blocks coupled to exemplary linkage 2 as shown in
FIG. 2 are oriented and positioned in different parts of
three-dimensional space. Further, an exemplary linkage 2 may be
configured so that the positioning of the blocks coupled thereto in
the three-dimensional space is substantially maintained. Because of
its flexibility, an exemplary linkage 2 may also be configured so
that its parts have different positions in three-dimensional space
as bricks are displaced from one position to another. Further
orientation arrangements capable with an exemplary linkage 2 may
also be understood with reference to FIGS. 11C, 15, 18B-D, and
their related, interrelated, and interchangeable disclosures.
[0032] With reference to FIGS. 3A-D, exemplary linkages 2 may be
shown with different heads 1. For ease of reference, head 1 may be
considered the portion of an exemplary linkage 2 that may be used
to join an exemplary linkage 2 to exemplary bricks 10, although
tail 0 may have the same or similar purpose for the same or
different bricks 10. Thus, head 1 has no restrictive beginning
point, but may comprise one end of an exemplary linkage 2.
Likewise, tail 0 has no restrictive beginning point, but may
comprise the other end of an exemplary linkage 2 opposite head 1.
In an exemplary linkage 2 of the wire-type, such linkage may have a
head 1 and a tail 0 at either end. While an exemplary linkage 2 has
thus far been described in such manner, the inventive system may
utilize linkages 2 made up of multiple heads 1/tails 0 depending on
design purposes, e.g., linkages with "Y" shapes, "X" shapes,
cruciform, and others. Unless otherwise indicated, embodiments
showing only one head 1 or tail 0 of an exemplary linkage 2 do not
foreclose the existence of any number of heads 1, tails 0, and
linkage 2 types previously described. Additionally, while a head 1
or tail 0 may be used to illustrate an embodiment and describe it,
it should be understood that descriptions of one may apply equally
to the other.
[0033] An exemplary linkage 2 may be shown in FIG. 3A as having a
head 1 comprised of a conical or spherical terminus 11 and one or
more threads or windings 12. While shaped in this fashion, terminus
11 may be flat, concave, or any other surface. In another exemplary
embodiment illustrated by FIGS. 3B and 3C, an exemplary linkage 2
may have a head 1 comprised of bumps or curved recesses 3 about the
linkage's circumference and/or perimeter. In yet another exemplary
embodiment, which may be illustrated by FIG. 3D, an exemplary
linkage 2 may have a head 1 comprised of one or more discs 3a
separated by one or more recesses 3. The head 1 of an exemplary
linkage 2 may comprise one or more of the aforementioned and other
surface features for the purposes of serving as part of an
exemplary system described herein. Such contours may be made by 3D
printing, laser machining, laser sintering, CNC machining, lathes,
molding, extrusions, taps, and/or dies.
[0034] The illustrative embodiment of FIG. 4A may show parts of an
exemplary inventive system. According to this illustrative
embodiment, an exemplary linkage 2 may have a head 1 comprised of
round surfaces 3. An exemplary linkage 2 in FIG. 4A may be received
within exemplary brick 10 through opening 5. In this illustrative
embodiment, exemplary brick 10 may be hollow inside so that it may
have a cavity 9 with inner surface 8 and an outer surface 7.
Disposed within cavity 9 of exemplary brick 10 may be an exemplary
socket 15.
[0035] According to one aspect of an inventive system, an exemplary
socket 15 may be sized, shaped, and/or contoured to fit partially
or completely within cavity 9, e.g., as a prismatic, spherical, or
other polyhedron shape, in order to receive and hold a head 1 or
tail 0 of an exemplary linkage 2. For example, an exemplary socket
15 may be such that it does not inhibit the use of opening 5 or
exit 6 to allow exemplary brick 10 to combine with other building
blocks. Alternatively, an exemplary socket 15 may be contoured so
that when placed within an exemplary brick 10, it may have recesses
sized and shaped like an exemplary opening 5 or exit 6 to allow
exemplary brick 10 to combine with other bricks. In an exemplary
embodiment, an exemplary socket 15 may be a component of an
exemplary inventive system that may be placed within exemplary
brick 10 so as not to disturb its uses and functions for assembly
with other building blocks.
[0036] As shown in FIG. 4A, an exemplary socket 15 may comprise a
channel 16 into which an exemplary linkage 2 may be received.
Channel 16 may be sized and shaped to complement head 1 of linkage
2 when received within an exemplary socket 15. Alternatively,
channel 16 may be sized and shaped so that head 1 of linkage 2
friction-fits within an exemplary socket 15. For example, as shown
in FIG. 4B, an exemplary inventive system 20 may have a linkage 2
with a head 1 comprised of a plurality of spherical surfaces 3.
When inserted into exemplary brick 10 containing an exemplary
socket 15, spherical surfaces 3 compress walls of cylindrical
channel 16 while walls of channel 16 press against spherical
surfaces 3. In this manner, channel 16 may be molded so that
compression surfaces 15a hold or brace the head 1 of linkage 2 so
as to maintain its reception in an exemplary socket 15 and thereby
retention in exemplary brick 10. According to another exemplary
embodiment, channel 16 may be sized and shaped for bracing an
exemplary linkage 2 but allow passage of other exemplary building
blocks known to those skilled in the art, e.g., as may be
illustrated in FIGS. 5 and 14D.
[0037] In an exemplary embodiment, channel 16 may possess an
average cross-section (as measured from its furthest depth to its
terminus at the surface of an exemplary socket 15) that is greater
than 0% and up to about 15% smaller than the average cross-section
of head 1 or tail 0 of an exemplary linkage 2 (as measured from the
end of linkage 2 to the terminus of the contours on either head 1
or tail 0). In an exemplary embodiment, channel 16 may be about 13%
smaller in average cross-section compared to that of head 1 or tail
0 of linkage 2. Alternatively, a cross-section or average
cross-section of channel 16 may be up to any percentage smaller
than a cross-section or average cross-section of head 1 or tail 0
of linkage 2 so long as the introduction of such head 1 or tail 0
of linkage 2 does not cause an exemplary socket 15 to go beyond its
modulus of resilience at a given temperature and hardness.
[0038] With reference to the illustrative embodiment of FIG. 4C,
another exemplary socket 15 within exemplary brick 10 may have a
contoured channel 16 having one or more grips 17 for gripping or
bracing an exemplary linkage 2, which may have a head 1 comprising
disks 3a and recesses 3. As previously described with respect to
channel 16, an exemplary contoured channel 16 may have the same
characteristics, such as being complementary to the shape of head 1
or be slightly smaller to create a friction-fit by way of
compression surfaces 15a. In another exemplary embodiment, channel
16 may not be complementary to linkage 2 and/or head 1 so as to
create more gripping, hugging, and/or bracing surfaces within
channel 16.
[0039] As illustrated in the exemplary embodiment depicted in FIG.
4D, an exemplary joint 20 may comprise an exemplary linkage 2 with
a head 1 comprised of alternating discs 3a separated by recesses 3
braced by grips 17 in an exemplary socket 15. According to this
exemplary embodiment, complimentary grips 17 and recesses 3 may
result in a robust connection between linkage 2 and exemplary brick
10. For example, where an exemplary socket 15 may be made of an
elastomer material, a linkage 2 with a head 1 comprising
alternating discs 3a and recesses 3 may be pushed against the grips
17 of an exemplary socket 15 causing them to deflect distally from
the direction of entry of the linkage 2. According to such an
embodiment, an exemplary elastomer socket 15 with elastic grips 17
may allow the grips 17 to deflect back towards the direction of
entry of linkage 2 after a linkage 2 contour passes such that they
are substantially found between the linkage 2 contour (as
illustrated, discs 3a) and adjacent to the recesses 3 of the head
1. With respect to this embodiment, the elasticity of grips 17 may
allow them to permit entry of head 1 of linkage 2 when inserted
into the socket 15 while substantially resisting departure of head
1 from an exemplary socket 15 if linkage 2 experiences forces
tending to displace it from an exemplary socket 15, e.g., tension
forces.
[0040] In an alternative embodiment illustrated with respect to
FIGS. 4F and 4G, grips 17 may be modified to allow easier
displacement from an exemplary socket 15 (e.g., sloped grips 17a)
and/or discs 3a may be modified to allow head 1 of an exemplary
linkage 2 to more easily displace from gripping socket (e.g., bowl
discs 3b).
[0041] In another exemplary embodiment illustrated by FIG. 4E, an
exemplary brick 10 may have a crevice 8a in inner surface 8. An
exemplary crevice 8a may be of any cross-section and may span
partially or fully about inner surface 8, including about the
circumference of inner surface 8, in an intermittent arrangement
about inner surface 8, and/or in a continuous/discontinuous spiral
pattern. Preferably, crevice 8a may be located between opening 5
and exit 6 of exemplary brick 10. Preferably, crevice 8a may be
only within cavity 9. Alternatively, an exemplary crevice 8a may be
a through-hole 7a connecting inner surface 8 to outer surface 7. As
will be further described, a through-hole crevice 8a may be useful
for selective operation of system 20.
[0042] Further illustrated in the illustrative embodiment of FIG.
4F may be an exemplary socket 15 having wings 15a. Exemplary wings
15a may be configured to be received within an exemplary crevice 8a
within exemplary brick 10. While wings 15a may be shown as single
extensions from the circumference of a circular socket 15, they may
also be shaped to spiral about the outer surface of an exemplary
socket 15 so that when met with complementary spiral crevice 8a,
such a socket 15 may be screwed into exemplary brick 10.
Accordingly, an exemplary interaction between crevice 8a and wings
15a may further increase the bracing capability of an exemplary
socket 15 in an exemplary joint 20.
[0043] As previously described with respect to a through-hole
crevice 8a, reception of an exemplary socket 15 within an exemplary
brick 10 with such a through-hole 7a, such as may be illustrated
with respect to FIG. 4E, may possess the added advantage of being
released from exemplary brick 10 by inserting a pin or pencil point
into through-hole 7a to depress wing 15 located in the through-hole
crevice 8a. In so doing, an exemplary socket 15 may be released
from cavity 9. Crevice 8a and wings 15a may be complementarily
shaped and/or sized to increase friction there between, e.g.,
crevice 8a may be triangular in cross-section while wings 15a were
circular or rectangular. An exemplary brick 10 possesses one
crevice 8a that is substantially spherical in shape while an
exemplary socket 15 may have one wing 15a that is substantially
spherical in shape. Other varieties and combinations may be
configured for particular needs.
[0044] As illustrated in FIGS. 4A-G, an illustrative inventive
system 20 may be such to reduce the propensity of an exemplary
linkage 2 from disengaging from exemplary brick 10 by way of an
exemplary socket 15. An exemplary socket 15 may be made of polymer,
and more particularly, an elastomer material or thermoplastic,
preferably an elastomer such as rubber or silicone. As an
elastomer, an exemplary socket 15 may be advantageously suited for
insertion in exemplary brick 10 by way of a calendaring process 102
shown in FIG. 4H. While other forms of calendaring processes may be
understood to those skilled in the art, the exemplary calendaring
process illustrated diagrammatically in FIG. 4H may show
calendaring wheels C compressing elastomer socket 15 so as to fit
within exit 6 of an exemplary brick 10.
[0045] With reference to the illustrative embodiment of FIG. 5, an
exemplary linkage 2 may be comprised of a head 1 for reception
within a channel 16 as well as intermediary ribs 3c/3d extending
from its own surface structures, which may be the same as or
different from those on head 1 and proximal or distal to the same,
for reception in a separate channel 16a of a separate socket 15 in
a separate exemplary brick 10. For example, an exemplary linkage 2
may have a head 1 comprising recesses 3 and fins 3a. The same
exemplary linkage 2 according to this illustrative embodiment may
have grooves 3c with extensions 3d. A first exemplary brick
10.sub.1 may be coupled to head 1 of an exemplary linkage 2 by way
of an exemplary socket 15 such that linkage 2 does not pass from
exemplary brick 10.sub.1 opening 5 to exit 6 via channel 16.
Grooves 3c and extensions 3d may also friction fit a second
exemplary brick 10.sub.2 by way of a second through-socket 15.sub.1
whose through channel 16a allows full passage of an exemplary
linkage 2 from opening 5 to exit 6 of the exemplary brick 10.sub.2.
Alternatively, one or more exemplary bricks 10.sub.3 may comprise
channels 16b that slidingly or frictionally engage the
non-contoured surface of an exemplary linkage 2. Alternatively,
exemplary bricks 10.sub.3 may also slidingly or frictionally engage
both contoured and non-contoured surfaces of an exemplary linkage
2. While exemplary brick 10.sub.3 may be illustrated as a small
exemplary brick, e.g., a 1.times.1 Lego.RTM. plate, exemplary brick
10.sub.3 may be any size and shape with a channel 16b through its
surfaces.
[0046] An exemplary multi-surface linkage 2 may be able to interact
with numerous exemplary bricks 10.sub.n (where n is any integer) to
provide building points for other exemplary blocks, e.g., exemplary
building blocks 100, on its posable surface. In other words,
exemplary bricks 10.sub.2 may be anchored by surface structures
intermediary of linkage 2's head 1 and tail 0, e.g., exemplary
block 10.sub.3. While such exemplary bricks have been shown having
a through socket 15.sub.1 other forms of exemplary bricks 10.sub.2
and 10.sub.3, with and without an exemplary socket 15 that permit
full passage of an exemplary linkage 2 there through, are also
suitable. Thus, an exemplary linkage 2 may act as the foundation
for building numerous block structures on its flexible surfaces and
may serve as a universal scaffolding for exemplary building block
assemblies 100.
[0047] With reference to the illustrative embodiments of FIGS.
6A-B, an exemplary brick 10 may contain an exemplary socket 15
comprising a channel 16 having spiral threads 18 for complementary
screw-threads 12 corresponding to head 1, tail 0, and/or terminus
11 of an exemplary screw linkage 2. As illustrated in these
illustrative embodiments and may be used in others, an exemplary
socket 15 may possess rounded surfaces 15c to reduce material usage
and cost of fabrication. Alternatively, rounded surface 15c may
take the form of a funnel-like structure adjacent an opening 5 or
exit 6 to facilitate reception of an exemplary linkage 2 within the
channel 16. An exemplary socket 15 may also be porous or
sponge-like in material composition. While terminus 11 of exemplary
screw linkage 2 may be pointed or conical, terminus 11 of an
exemplary screw linkage 2 may be substantially flat, e.g., like the
terminus 11 of linkage 2 in FIG. 7B.
[0048] As illustrated in FIG. 6B, screw threads 12 on the head 1 or
tail 0 of an exemplary linkage 2 may be similar to a screw or other
threaded fastener known to those skilled in the art. Likewise,
threads 18 may be complementary to such screw threads 12 to allow
for a robust connection between screw linkage 2 and exemplary screw
socket 15. Alternatively, an exemplary screw linkage 2 with threads
12 may be used with sockets 15 without threads 18 and rely on the
modulus of resilience of an exemplary socket 15 to brace such screw
linkage 2 threads. One advantage of using an exemplary screw socket
15 in the aforementioned embodiments may be to establish a greater
amount of surface contacts between screw linkage 2 and its thread
surfaces 12 and an exemplary socket 15. Combining the various
retention features described, e.g., grips 17 and/or screw channel
16, in one exemplary socket 15 may provide additional linkage 2
retention properties and advantages. For example, for an exemplary
linkage 2 with a screw head 1 with threads 12 and a recess 3 distal
of the threads 12, one may provide an exemplary socket 15 having a
grip 17 proximal to the entry of the channel 16 and screw threads
18 distal from the entry so that the exemplary screw linkage 2 may
both screw into an exemplary socket 15 and be restrained from
movement by grip 17.
[0049] As illustrated in FIG. 7A, an exemplary brick 10 may be
solid except for opening 5 in which a channel 16 with threaded wall
18 may be found and an exit 6 for receipt of an adjoining exemplary
brick 10. Exemplary screw linkage 2 may then screw into exemplary
brick 10 as shown in FIG. 7B. According to the illustrative
embodiment of FIG. 7B, an exemplary screw linkage 2 may be received
within screw channel 16 and screwed into threaded wall 18 using its
threads 12 extending from the head 1 and/or tail 0 of screw linkage
2. The shape and/or dimensions of screw channel 16 may be based on
the needs and loads of screw linkage 2. Alternatively, the shape
and/or dimensions of screw channel 16 may be contingent on the
shape and/or dimensions of exemplary brick 10. For example, screw
channel 16 may be located adjacent to threads 18 found on opening 5
and/or exit 6. In an exemplary embodiment, exemplary brick 10 with
screw channel 16 may be capable of assembly to other bricks (not
shown) using the geometries of opening 5 and exit 6 even though it
may have a screw channel 16 embedded therein or threads 18 on the
inside of opening 5 and/or exit 6. This is the same for the other
embodiments having a screw channel 16 in a socket 15.
[0050] Screw channel 16 may be made by boring out an exemplary
brick 10 and using a tap and die to create the threads 18 of the
channel for an exemplary screw linkage 2. Alternatively, a lathe
may be utilized. Further alternatively, as disclosed herein,
exemplary brick 10 containing a screw channel may be made using 3D
printing technologies known to those skilled in the art.
[0051] In another exemplary embodiment illustrated by FIG. 7B,
exemplary screw linkage 2 may be received within the material of
exemplary brick 10. According to such embodiments, exemplary brick
10 may have an opening 5, exit 6, a cavity 9, and a screw channel
16 disposed between opening 5 and cavity 9 or between exit 6 and
cavity 9. The screw channel 16 may be the only channel with threads
18 for interaction with threads 12 of terminus 11 of screw linkage
2. Alternatively, threads 18 may be found within opening 5 or exit
6 of an exemplary brick 10 and optionally may require an additional
screw channel 16. The extension of threads beyond screw channel 16
to opening 5 and/or exit 6 may be provided for in any of the other
disclosed embodiments involving screw linkages 2. According to the
alternative embodiment where only opening 5 and/or exit 6 possess
threads 18 may reduce the amount of threading required in exemplary
brick 10 and/or an exemplary socket 15.
[0052] Other exemplary screw bricks 10 may be illustrated by way of
FIGS. 7C-E. For example, an illustrative embodiment of an exemplary
screw brick 10 as shown in FIG. 7C may not have an opening 5 but
may have a screw channel 16, an exit 6, and a space 9 for assembly
to other bricks (not shown). Alternatively, an exemplary screw
brick 10 may only have a screw channel 16 and no other structures.
In the illustrative embodiment of FIG. 7D, an exemplary screw brick
10 may have a plurality of screw channels 16 of various sizes,
threading, and orientations. As illustrated, exemplary screw brick
10 of FIG. 7D may comprise one type of screw channel 16p and 16q,
and another type of screw channel 16r in various sides of exemplary
brick 10. According to this illustrative embodiment, an exemplary
multi-screw port brick 10 may permit numerous flexible linkages 2
to extend therefrom. While exemplary brick 10 may be illustrated as
rectilinear, there is no requirement that exemplary brick 10 need
be so. When an exemplary brick 10 may comprise one or more screw
channel 16s about a spherical surface, such an exemplary brick 10
may allow for multiple screw linkages 2 disposed in various planes
in three-dimensional space at one time, e.g., FIG. 7E.
[0053] While screw channels 16p/16q/16r are oriented at 90 degrees,
such screw channels do not need to be orthogonal to one another but
may have more acute and/or obtuse angles with respect to one
another. An exemplar of an exemplary brick 10 having an angled
screw channel 16 may be understood with respect to FIG. 7E. An
exemplary brick 10 may have one or more angled screw channels
16s/16t within its surfaces, including in corners or on other
points of the exemplary brick 10 surface.
[0054] In another exemplary embodiment illustrated by FIG. 7E, an
exemplary brick 10 may have a hybrid of rectilinear, rounded or
spherical or hemispherical surfaces into which screw channel 16s
may be disposed. In such embodiments, an exemplary screw linkage 2
may be oriented in a plane other than one orthogonal to the surface
on which exemplary brick 10 may sit, e.g., where exemplary brick 10
assembles to other bricks (not shown), screw channel 16 may be
oriented at less than 90 degrees from the exemplary brick-to-brick
assembly surface. Similarly, in other exemplary embodiments, a
plurality of screw channels 16 may be disposed on an exemplary
brick 10 so that they are both oriented with respect to one another
and exemplary brick 10 at non-orthogonal positions and/or less than
90 degrees from any exemplary brick-to-brick assembly surface.
[0055] As described, an illustrative exemplary hybrid block 50 may
be composed using 3D printing or other formation methods known to
those skilled in the art. As illustrated in FIG. 7F, an exemplary
hybrid building block 50 may comprise an exemplary socket 15
located in a cavity 9 between a screw channel 18 and opening 5. As
illustrated, cavity 9 may hold an exemplary socket 15 having
surface contours, such as grips 17, for gripping recesses 3 of an
exemplary linkage 2. Accordingly, such an exemplary hybrid block 50
may allow an exemplary screw linkage 2 having threads 12 and
recesses 3 about its length to have a plurality of coupling regions
within exemplary block 50. In the illustrative embodiment of FIG.
7F, an exemplary linkage 2 may screw into exemplary block 50 while
also being gripped by grips 17 of an exemplary socket 15. As
illustrated, an exemplary socket 15 may act as a diaphragm or
friction washer for an exemplary building block system joint 20.
Any variety and order of linkage recesses 3, threads 12, and
surfaces 3a-g, as described elsewhere, may be used up and down an
exemplary linkage 2. As such, exemplary hybrid block 50 may have
numerous sockets 15 and receiving cavities 9, with and without
contours, e.g., threads 18, and in any order to accommodate a
particular exemplary linkage 2 and/or add to retention of such
linkage 2.
[0056] With reference to the illustrative embodiments of FIGS. 8,
8A-B, 9A-B, 10A-C, and 11A-C, an exemplary clamshell-type brick 30
(hereinafter referred to as "brick 30") may comprise a plurality of
exemplary brick portions, for example, 10a and 10b, with inner
surfaces 8a and 8b, respectively, coupled via flexible portion 31.
Flexible portion 31 may be a piece of material of the same or
different composition of other parts of exemplary brick 30. In one
exemplary embodiment, exemplary brick 30 may be made from a
polymer, such as an acrylic, while flexible portion 31 may be
comprised of a more malleable polymer. In an exemplary embodiment,
flexible portion 31 may be capable of allowing exemplary brick 30
to open and close so that portions 10a and 10b abut one another so
that surfaces 8a and 8b and outer surface 7 are substantially
continuous. According to other illustrative embodiments, flexible
portion 31 may be configured to allow exemplary brick 30 to open
and close like a clam shell so that, when closed, substantially no
gaps exist in one or more of outer surface 7, inner surfaces 8a and
8b, opening 5, or exit 6. While the illustrative embodiment of
FIGS. 8, 8A-8B illustrate one flexible portion 31 in the
longitudinal direction, numerous other flexible portions 31 may be
found longitudinally about exemplary brick 30 to allow opening and
closing of the same.
[0057] As further illustrated by the illustrative embodiment of
FIG. 8, an exemplary brick 30 may be opened about flexible portion
31 such that two inner surfaces 8a and 8b for two halves 10a and
10b, respectively, are visible when viewing exemplary brick 30.
Teeth 32a and 32b extend outwardly from the inner surfaces 8a and
8b, respectively. While teeth 32a/32b have been shown with
rectangular cross-sections, any shape may be suitable for use for
the construction of teeth 32a/32b. A view of an exemplary
cross-section made by line A-A in FIG. 8 may be illustrated in FIG.
8A. As shown, the opening 5 of exemplary brick 30 may be opened
about flexible portion 31 exposing teeth 32a/32b and the upper
surfaces 7 of halves 10a and 10b.
[0058] A view of an exemplary cross-section made by line B-B in
FIG. 8 may be illustrated by FIG. 8B. As illustrated, an exemplary
brick 30 may be opened so that teeth 32a/32b are exposed for the
exemplary brick 30 halves, 10a and 10b, respectively. Again, these
halves 10a/10b open about flexible portion 31. FIG. 9A illustrates
an exemplary operation of an exemplary brick 30. In the
illustrative embodiment of FIG. 9A, an exemplary linkage 2 with
recesses 3 and fins 3a at head 1 may be configured to receive a
complimentarily shaped tooth 32a/32b. Accordingly, the toothed
exemplary clam brick 30 illustrated in these embodiments may be
used to lock in place an exemplary linkage 2 having a properly
configured head 1 based on the surface structure of an exemplary
linkage 2 and the inner surface 8a/8b structures of exemplary clam
brick 30.
[0059] In another exemplary embodiment, exemplary brick 30 may be
able to retain an exemplary linkage 2 with or without additional
supports. In the former scenario, a hollow exemplary cap brick 40
may be used in which a hole sized to fit an exemplary linkage 2
slides down linkage 2 to the juncture between linkage 2 head 1 and
exemplary clam brick 30. An exemplary cap brick 40 may have a peg
portion 41, a ridge portion 43, a through-hole 44, and a receiver
portion 42 for reception with other exemplary bricks
10/30/40/50/60/70/100. According to the illustrative embodiment of
FIG. 9A, an exemplary cap brick 40 receiver portion 42 may receive
within itself the opening 5 of exemplary clam brick 30.
Accordingly, exemplary cap brick 40 may preclude exemplary clam
brick 30 from opening by virtue of its holding the opening 5 of
exemplary clam brick 30 together, as may be understood with respect
to FIG. 9B. Further exemplary bricks (not shown), may be attached
to the peg portion 41 as needed. Exemplary cap brick 40 may take
various other forms and sizes as needed and may be a portion of a
building block that does not have a hollow passage for an exemplary
linkage 2 there through, e.g., a 2.times.2 Lego.RTM. plate brick
may have one stud that is an exemplary cap brick 40 and the
remaining three studs or pegs as provided in the prior art.
[0060] In another exemplary embodiment of exemplary clam brick 30,
as may be seen with reference to FIG. 10A, halves 10a and 10b may
have on their inner surfaces 8a and 8b, respectively, a male
receptor 33a and a female receptor 33b, each configured to couple
to the other in a nested or overlapping arrangement. In use, an
exemplary linkage 2 with a head hole 3g in head 1 may be configured
for reception within exemplary brick 30 and aligned with receptors
33a/b so that when exemplary clam brick 30 closes, the receptors
33a/b intersect within and/or through head hole 3g of head 1 of an
exemplary linkage 2. Accordingly, as illustrated in FIGS. 10B and
10C an exemplary linkage may be threaded by the receptors 33a/b
when exemplary clam brick 30 is closed. As may be further
illustrated in FIG. 11A, any number or arrangement of receptors
33a/b may be utilized for the particular purpose. As previously
stated, receptors 33a/b may be any shape or configuration suitable
for use as holding an exemplary linkage 2 received in the exemplary
brick 30.
[0061] With respect to the illustrative embodiments of FIGS. 11A-C,
an exemplary clam brick 30 may contain a groove 34 in outer surface
7 of its halves 10a/b for receiving a brace 35 therein. As
illustrated, an exemplary groove 34 may be of any type of
cross-section for the purpose and brace 35 may be made out of any
type of material capable of holding an exemplary brick 30 together.
In an exemplary embodiment, groove 34 may be a rectangular
cross-section configured so that when brace 35 is placed therein,
the brace 35 and outer surface 7 of exemplary brick 30 are
substantially aligned.
[0062] As illustrated in FIG. 11C, a brace 35, which may preferably
be made of an elastomer, such as rubber, is shown as being wrapped
tightly about exemplary brick 30 while an exemplary linkage 2 is
free to move outside of exemplary brick 30. As another exemplary
embodiment of the posability and universal orientation of an
exemplary linkage 2 may be further illustrated in FIG. 11C.
[0063] As illustrated in FIG. 11C, an exemplary linkage 2 may exit
an exemplary brick 30 at point "A." An exemplary linkage 2 may be
undulated at point "B" so that it enters point (0.5, 0.5, -0.5),
which means that as this part of linkage 2 ascends and proceeds to
the right, it also goes behind point "A." Point "C," at coordinates
(1, 2, -0.75), illustrates that an exemplary linkage 2 may be
further bent behind point "B" while gravitating upwardly and
further ahead of point "A" in the horizontal plane. Further
illustrating the universal positioning of an exemplary linkage 2,
point "D" located at the terminus 11 of tail 0 (which is shown with
spiraling threads 12 thereon) may have coordinates (-2, 4, 1)
thereby showing that the tail 0 of an exemplary linkage 2 may be
bent behind its origin point and brought forward of the origin,
even though it began with bending behind the origin (as in points
"B" and "C"). As described, an exemplary linkage 2 would be
configured to maintain bricks coupled to either of its ends in this
configuration in three-dimensional space. Alternatively, an
exemplary linkage 2, by virtue of its flexibility, may be
configured to change these illustrated coordinates when displacing
bricks coupled to its ends.
[0064] With reference to FIGS. 12A-C and FIGS. 13A-C, an exemplary
porous brick 60 may be one possessing multiple cavities/apertures
in its construction. For example, with respect to the exemplary
porous brick 60 illustrated in FIG. 12A, such exemplary brick 60
may have one or more openings 5 extending from its outer surface 7,
a first cavity 9 leading to one or more exits 6 and additional
cavities 9a, and one or more inner surfaces 8 which may have one or
more crevices 8a. In an exemplary embodiment, exemplary porous
brick 60 may be an Erling Lego-like brick.
[0065] An exemplary porous brick 60 may be further illustrated in
FIG. 12A with views from the front, rear, and side of the exemplary
brick 60. Other types of exemplary porous bricks 60 may be readily
understood by persons skilled in the art and may be used in
addition to the illustrative exemplary porous brick 60 described.
One or more of the openings 5 of an exemplary porous brick 60 may
be configured to receive an exemplary linkage 2 therein.
[0066] In another embodiment in accordance with the illustrative
features of FIG. 12B, an exemplary porous brick 60 may receive
within its inner surface 8 an exemplary socket 15 adapted to fit
within one of its cavities 9 so as to close off exit 6. In another
embodiment, an exemplary socket 15 may have one or more wings 15a
configured to be received within a crevice 8a in one of the
cavities 9 of exemplary porous brick 60. An exemplary fitting of an
exemplary socket 15 within exemplary porous brick 60 may provide a
channel 16 through opening 5 for reception of an exemplary linkage
2 therein. According to the illustrative embodiment of FIG. 12B, an
exemplary channel 16 may be a contoured channel 16 which may
contain one or more grips 17. According to an exemplary method of
use of an exemplary porous brick 60 with an exemplary socket 15,
the first exemplary step may be to align an exemplary socket 15 to
be placed within a complementary inner surface 8 of an exemplary
porous brick 60 cavity. The second exemplary step may be to align
socket channel 16 with an opening in the exemplary porous brick 60.
The third exemplary step may be to use an exemplary linkage 2 head
1 to engage the combination of exemplary porous brick 60 and an
exemplary socket 15 through an opening 5. The fourth exemplary step
may be to couple exemplary porous brick 60 to adjacent exemplary
bricks to preclude the disposition of an exemplary socket 15 from
within exemplary porous brick 60 while in use. According to an
exemplary embodiment, the third and fourth exemplary steps may be
had in either order depending on needs. Further, while a contoured
channel 16 may be shown, any other channels 16 (e.g., screw
channels) may be contemplated as well as contoured openings 5
and/or exits 6 of such exemplary bricks 60 as per other
embodiments.
[0067] With reference to FIG. 12C, an exemplary porous brick 60
alone or in combination with an exemplary socket 15 may be
connected to an exemplary brick assembly 100 in which its cavity 9
where an exemplary linkage 2 may be received is closed off by
surrounding exemplary bricks in the exemplary brick assembly 100.
Exemplary brick assembly 100 may be comprised of one or more bricks
compatible with exemplary porous brick 60 and receptive to its
attachment and/or connection. As shown in the illustrative
embodiment of FIG. 12C, an exemplary linkage 2 may be received
through opening 5 of exemplary porous brick 60, which houses an
exemplary socket 15 within its cavity 9, and is juxtaposed by
exemplary brick assembly 100 such that an exemplary socket 15 is
substantially confined within exemplary porous brick 60. According
to this exemplary embodiment, an exemplary linkage 2 may have a
contoured head 1. In an exemplary embodiment, which happens to be
illustrated in FIG. 12C, recesses 3 and fins 3a of head 1 interact
with grips 17 of contoured channel 16 of an exemplary socket 15 to
substantially retain an exemplary linkage 2 within exemplary porous
brick 60.
[0068] In one aspect of the illustrative embodiments of FIGS.
12A-C, an exemplary porous brick 60 may have the added benefit of
ease of removal of an exemplary linkage 2 from an exemplary socket
15. One exemplary illustration of such benefits may be shown with
respect to FIGS. 13A-C. As shown in the exemplary illustrative
embodiment of FIG. 13A, an exemplary linkage 2 may be used to expel
an exemplary socket 15 out of a cavity 9 in exemplary porous brick
60. In one view, the cross-section of an exemplary socket 15, shown
as socket 15y, shows engagement of head 1 of an exemplary linkage 2
by one or more surface contours, such as fins 3a and recesses 3,
although others are contemplated and may be understood to those
skilled in the art. As shown in FIG. 13A, the cross-sectional view
of an exemplary linkage 2 socket channel 16y illustrates an
exemplary engagement with head 1 of an exemplary linkage 2, as
disclosed.
[0069] FIG. 13B illustrates a view of the exemplary porous brick
60, an exemplary socket 15, and exemplary linkage 2 arrangements in
another aspect of operation. According to the illustrative
embodiment of FIG. 13B, while still engaged within an exemplary
socket 15 and exemplary porous brick 60 but with an exemplary
socket 15 expelled from exemplary porous brick 60, an exemplary
linkage 2 may be rotated, e.g., within any 360 degree movement, but
more preferably 180 degrees, within opening 5 such that the
exemplary socket 15 may be turned (as shown by the arrow adjacent
the letter "T") in a different orientation, so that a side passage
16x faces perpendicular to exemplary porous brick 60. Side passage
16x may be a passage from either side of socket channel 16 by which
socket 15 may be slidingly disengaged from head 1 of an exemplary
linkage 2. In an exemplary embodiment, a portion 15x of an
exemplary socket 15 may be removed (as shown by the arrow adjacent
the letter "R") by slipping head 1 of an exemplary linkage 2 out of
socket channel 16 by way of side passage 16x, as may be illustrated
by FIG. 13C.
[0070] Any disclosed socket 15 may have one or more side passages
16x to allow an exemplary linkage 2 to disengage from an exemplary
socket 15 in either exemplary porous bricks 60 or other exemplary
bricks 10 as disclosed. Side passages 16x may be used to allow
users to switch different sockets 15 depending on needs, or allow
for further materials and/or exemplary bricks 10/30/40/50/60/70 to
be placed on an exemplary linkage 2 while constructing.
Alternatively, slide passages 16x embodiments of exemplary sockets
15 may be preferable for replacing sockets 15 after repeated
use.
[0071] In the illustrative embodiments of FIGS. 14A, 14B, 14C and
14D, yet other mechanisms of linkage systems may be disclosed. For
example, FIG. 14A shows an exemplary brick 70 with a passage 5/6
through its thickness for reception of parts much larger in
diameter than exemplary linkage 2. Such exemplary bricks 70 may be
found in Lego.RTM. Technic sets or other non-Lego.RTM. building
block systems, e.g., K'nex. Exemplary bricks 70 may have surface
contours 7a, e.g., an indentation in surface 7, that surround or
are adjacent to their passages 5/6. An exemplary contour 7a may be
an indentation in the surface 7 of exemplary brick 70.
[0072] As illustrated in FIG. 14B, an exemplary linkage 2 with a
tail 0 may be placed within the cavity 9 of the exemplary brick 70
connected by passage 5/6. An adaptor socket 19 may possess an
exemplary channel 16 configured as other disclosed channels of
sockets 15 for reception of an exemplary linkage 2 therein. An
exemplary adaptor socket 19 may possess one or more anchors 19a
substantially complementary to surface contours 7a of exemplary
brick 70. Exemplary anchors 19a may take the form of lips, rims, or
pegs, but may be any other structures that may serve to hold
adaptor socket 19 within exemplary brick 70, either on surface
contours 7a of exemplary brick 70 or crevices 8a in exemplary brick
70 (see FIG. 14C). Exemplary surface contours 7a and crevices 8a
may be utilized within exemplary brick 70 to allow for friction
fitting of adaptor socket 19 within the exemplary brick 70 cavity
9.
[0073] An exemplary adaptor socket 19 may be sized and shaped to
fit within the cavity 9 of exemplary brick 70 so as to allow an
exemplary linkage 2 to couple within exemplary brick 70 despite the
fact that exemplary brick 70 may not normally hold an exemplary
linkage 2 to keep it from moving or exiting the brick or block.
This may be done by making adaptor socket 19 larger than the
passage 5/6 of exemplary brick 70 to allow an exemplary adaptor
socket 19 to friction fit within the cavity 9 of the exemplary
brick 70. Alternatively, adaptor socket 19 may have surface
contours 19b, which may be any size and cross-section as needs may
be, that when combined with crevices 8a in exemplary brick 70
resist removal of the adaptor socket 19 while in use.
[0074] In an exemplary adapted brick 70 system illustrated by FIG.
14C, an exemplary linkage 2 may have its tail 0 within channel 16
of adaptor socket 19, much like an exemplary linkage 2 may fit
within channel 16 of an exemplary socket 15. One or more crevices
8a within cavity 9 of exemplary brick 70 may receive one or more
adaptor surface contours 19b. Adaptor socket 19 may have a solid
portion that resists further displacement of an exemplary linkage 2
into channel 16. Alternatively, channel 16 of adaptor socket 19 may
allow for complete passage of an exemplary linkage 2 there through,
as illustrated by FIG. 14D. As illustrated in FIG. 14D, adaptor
contours 19b may be used to brace the surface contours 3 and/or 3a
of an exemplary linkage 2. Thus, an exemplary adaptor socket 19 and
any of its various surface contours 19b and anchors 19a may
function and be formed in the same manner as an exemplary socket 15
and its compression surfaces/wings 15a, e.g., elastomer material
and/or flexible material. Alternatively, an exemplary adaptor
socket 19 may be made of a more rigid material that may be screwed
or snapped into exemplary brick 70 by way of spiral contours 19b
coinciding with screw thread crevices 8a within cavity 9 of
exemplary brick 70. Other snap-to-fit arrangements of an exemplary
adaptor socket 19 and exemplary brick 70 may be used as well to
reduce tooling for an exemplary brick 70. An exemplary adaptor
socket 19 may also be removed from an exemplary linkage 2 in
similar manner to removal of an exemplary socket 15 as
disclosed.
[0075] An example of an exemplary linkage 2 posability may be
illustrated in FIG. 15. According to this illustrative embodiment,
FIG. 15 may show the positioning of exemplary blocks 10 and 50 in
three-dimensional space. As shown by the coordinates of points "A"
and "B" of exemplary blocks 10 and 50, respectively, an exemplary
linkage 2 may position the exemplary blocks and their adjoining
assemblies 100 and 200, respectively, in different positions in
three-dimensional space. These exemplary blocks may be further
moved with respect to one another by virtue of the flexibility of
an exemplary linkage 2. Exemplary linkage 2 may be disposed in
various parts of three-dimensional space, as may be illustrated by
FIG. 15, with reference to the coordinates of points "C" and "D" on
sections of an exemplary linkage 2. According to this illustrative
embodiment, the posability of an exemplary linkage 2 may
substantially maintain the parts of an exemplary linkage 2 in their
illustrated conformation, e.g., coordinates "C" and "D." Further,
the posability of an exemplary linkage 2 may substantially maintain
exemplary blocks 10 and 50 (or other exemplary blocks 30/40/60/70)
and their respective adjoining assemblies 100 and 200,
respectively, at their coordinates "A" and "B," respectively, over
a span of time.
[0076] Those skilled in the art may understand various other
methods and ways to secure an exemplary linkage 2 to an exemplary
brick 10/30/40/50/60/70 using other techniques. Exemplary bricks
10/30/40/50/60/70 that may open or "lock" an exemplary head 1 of an
exemplary linkage 2 may take various forms and variations,
depending on the needs of the construction. They may involve
exemplary bricks 10/30/40/50/60/70 with doors, clasps, or other
moveable parts that allow an exemplary head 1 of an exemplary
linkage 2 to enter and then resist exiting the exemplary brick
10/30/40/50/60/70.
[0077] For all exemplary embodiments, whether illustrated,
described, or understood from combination from the disclosures
herein, exemplary bricks 10/30/40/50/60/70, brace 35, and/or
sockets 15/19 may be printed using 3D printers known to those
skilled in the art, such as those made or used by MakerBot
Industries LLC of Brooklyn, N.Y. (Replicator series), Mcor
Technologies Ltd. of Co Louth, Ireland (Iris series and Matrix
series), 3D Systems Corp. of South Hill, S.C. (ProJet series and
CubePro series), Voxeljet AG of Friedberg, Germany (VX series and
VXC series), The ExOne Company of North Huntington, Pa. (S-Max,
S-Print, M-Print, M-Flex, X1-Lab, and Orion series), Arc Group
Worldwide of DeLand, Fla., and Stratasys, Inc. of Eden Prairie,
Minn. (Mojo, uPrint SE series, Objet series, Dimension, Fortus, and
printers using FDM, WDM, and Polyjet technologies). Exemplary
blocks or bricks 10/30/40/50/60/70, brace 35, and/or socket/adapter
15/19 may also be manufactured using extrusion, blow molding,
casting, or other fabrication methods known to those skilled in the
building block art. While an exemplary linkage 2 may also be 3D
printed, it may also be machined from metal or equivalent
materials, as described herein, using laser cutting and sintering,
extrusion, stamping, or CNC machining.
[0078] In an exemplary embodiment, an exemplary socket 15 may be 3D
printed within exemplary brick 10 while exemplary brick 10 is being
formed. Alternatively, exemplary brick 10 may be 3D printed and
socket 15 may be simultaneously 3D printed within exemplary brick
10 (e.g., an exemplary hybrid brick 50). 3D printing fabrication of
an exemplary brick 10 and socket 15 subsystem may be particularly
suited for mass production of such constructs and reduce the need
for physical assembly of the two structures post-fabrication.
[0079] In an exemplary embodiment, an Objet260 and Objet500 Connex
Multimaterial 3D printer manufactured by Stratasys, Inc. of Eden
Prairie, Minn. or a ProJet 5500X manufactured by 3D Systems Corp.
of South Hill, S.C. may form exemplary brick 10/30/40/50/60/70
using one material while also using another material for the socket
15, thereby reducing the assembly process and increasing the
likelihood of precise fitting between the socket 15 and exemplary
brick 10. Any and all embodiments described herein may be formed by
such simultaneous 3D printing processes known to those skilled in
the building block art (e.g., exemplary hybrid blocks 50).
[0080] In an exemplary embodiment, an exemplary socket 15 may be 3D
printed within exemplary brick 10 while exemplary brick 10 is being
formed. Alternatively, exemplary brick 10 may be 3D printed and
socket 15 may be simultaneously 3D printed within exemplary brick
10 (e.g., an exemplary hybrid brick 50). 3D printing fabrication of
an exemplary brick 10 and socket 15 subsystem may be particularly
suited for mass production of such constructs and reduce the need
for physical assembly of the two structures post-fabrication.
[0081] In an exemplary embodiment, an exemplary posable linkage 2
may be fabricated to comply with the June 2010 United States
Consumer Product Safety Commission Laboratory Test Manual for Toy
Testing, which is incorporated herein by reference in its entirety.
In one embodiment, exemplary posable linkage 2 will satisfy one or
more of subsections of section 9.2 and all of section 18, in
particular, section 9.2.4 Sharp Point Test, 9.2.5 Sharp Edge Test,
and 9.3.6 Flexure Test of the June 2010 United States Consumer
Product Safety Commission Laboratory Test Manual for Toy
Testing.
[0082] As further illustrated in the exemplary embodiments of FIGS.
16A-D, an exemplary linkage 2 may contain a component 2A of
diameter D.sub.M and a coating or cover 2B of thickness T.sub.C.
The cover or coating 2B may be one or more of the covers, coatings,
and/or tubings described herein and may be removable or permanently
attached to component 2A. Component 2A may be made of a flexible
metal. Alternatively, component 2A may be made of any other
material or combination of materials that in conjunction with
coating 2B has posability. An exemplar linkage 2 comprised of
component 2A and coating 2B may have a diameter D, although an
exemplary linkage 2 without a coating 2B may have the same or
similar diameter D.
[0083] D.sub.M and T.sub.C may be such that linkage 2 may be (i)
dimensioned so that it can be received within an opening 5 and/or
an exit 6 of an exemplary block 10; (ii) dimensioned so that it can
be received within fabric, flexible plastic, or elastomer tubing
(all of which may be a cover or coating 2B); (iii) dimensioned so
that D is within the range of diameters between those of opening 5
and those of exit 6 of an exemplary block 10; (iv) dimensioned to
have a D of approximately 0.123 inches to approximately 0.193
inches; and (v) be dimensioned as approximately 5- to approximately
14-gauge wire. In a most exemplary embodiment, D is about 0.12574
inches in diameter and component 2A is made from a flexible
aluminum armature wire. In another exemplary embodiment, D.sub.M
may be between about 0.0625 inches and about 0.12574 inches.
Additionally and/or alternatively, T.sub.C may be between about
0.0315 inches and about 0.0070 inches. Those skilled in the art may
readily understand that the features of linkage 2 in FIGS. 16A-D
are for purposes of illustration only, and these features may be
changed, interchanged, isolated, combined, or otherwise varied with
respect to any disclosed embodiments.
[0084] An exemplary coating 2B may be an elastomer selected from
the group comprising poly-isoprenes (e.g., rubber, natural rubber),
polyethylenes (e.g., Alathon, Alkathene, Fortiflex, Hi-fax,
Petrothene, Rigidex, Rotothene, Zendel), polystyrenes (e.g.,
Carinex, Dylene, Hostyren, Lustrex, Styron, Vestyron),
polyurethane, buna-N, butyl, SBR, neoprene (Chloroprene), silicone,
polybutadiene, and other flexible elastomers known to those skilled
in the art. An exemplary elastomer may be colored to match one or
more exemplary bricks 10/30-70 to which an exemplary posable
linkage 2 may couple and/or interconnect. Additionally, coating 2B
may have structures formed on it to allow connection between the
outer-most surface of linkage 2 and other Lego-like bricks. Those
skilled in the art would understand the use of plasticizers to
improve flexibility and ductility of an exemplary coating 2B.
[0085] In an exemplary embodiment, an exemplary linkage 2 may be
particularly dimensioned to friction-fit within the circular
opening 5 used on Erling Lego blocks, such as block 60 for example,
and others with such opening (block 10/30/40/50/70), and still be
maneuvered and posed in three-dimensional space while substantially
maintaining their conformation, e.g., have posability. According to
such an exemplary embodiment, an exemplary linkage 2 may have a
D.sub.M of about 0.0625 inches and a T.sub.C of about 0.03125
inches. In another exemplary embodiment, an exemplary linkage 2 may
have sufficient size to friction-fit within the cylindrical opening
5 used in Lego.RTM. Technic block systems, e.g., block 70, and/or
Lego.RTM. Erling blocks, e.g., block 60, and still be maneuvered
and posed in three-dimensional space while substantially
maintaining their conformation, e.g., have posability. According to
such an exemplary embodiment, an exemplary linkage 2 may have a
D.sub.M of about 0.0125 inches and a T.sub.C of about 0.00074
inches. In yet another exemplary embodiment, as may be further
discussed with respect to FIG. 16D, an exemplary linkage 2 may have
a coating 2B with a T.sub.C that is of such size and elasticity so
as to deflect when entering an opening 5 and/or 6 of an exemplary
building block, such as block 10/30-70, and yet exert a force
against the inner surfaces 8 of the opening 5/6 of that block that
is no greater than the modulus of resilience of the structure
making up the opening 5 and/or 6 of the block 10/30-70.
[0086] In one exemplary embodiment as illustrated by FIG. 16A, a
posable linkage 2 with a D of approximately 0.1257 inches may have
a 907A or 907C aluminum armature wire component 2A, such as the
type that is sold by The Compleat Sculptor, NY, N.Y., Sculpture
House, Skillman, N.J., and such that is made and sold by Arcor
Electronics, Niles, Ill. An exemplary component 2A may have a
D.sub.M of approximately 0.06285 inch and which may be coated with
an elastomer 2B substantially about its length having a T.sub.C of
approximately 0.031925 inches. More particularly, such an elastomer
2B may be a type of rubber.
[0087] In a first embodiment, 2*T.sub.C+D.sub.M may be the diameter
of an exemplary opening 5/6 in a Lego-like block. In a second
embodiment, 2*T.sub.C+D.sub.M is slightly greater than the diameter
of an exemplary opening 5/6 in a Lego-like block. In a third
embodiment, 2*T.sub.C+D.sub.M is equal to the diameter of the
circular opening 5 in an Erling Lego block 60. In a fifth
embodiment, 2*T.sub.C+D.sub.M is equal to or slightly greater than
the diameter of the circular opening 5 in an Erling Lego block 60.
Where 2*T.sub.C+D.sub.M is greater than the diameter of the
aperture into which linkage 2 head 1 or tail 0 is inserted, an
exemplary linkage 2 with such T.sub.C and D.sub.M may utilize its
elastomeric qualities or take advantage of the modulus of
resilience of the exemplary block opening 5/6. An elastomeric
coating 2B may be utilized due to its ability to deform in response
to contact forces and thereby allow a user to insert a linkage
comprising a component 2A with such a coating 2B into a Lego-like
block opening while maintaining friction-like contact, reduced wear
on the block opening, non-contact with metal, and/or minimal
manufacturing costs. Further and alternatively, an elastomeric
coating 2B may allow linkage 2 to have a D greater than the
diameter of block opening 5 and/or 6 because such a coating 2B can
deform while being inserted into the same (see, for example FIG.
16D and related disclosures). Depending on its elasticity, coating
2B may advantageously be applied to component 2A so that the
linkage 2 may have a diameter D greater than that of the opening
5/6 into which linkage 2 is to be placed, yet still effectively
friction fit with one or more exemplary blocks 10/30-70 to form one
or more robust joints 20.
[0088] According to an exemplary embodiment as illustrated in FIG.
16B, an exemplary linkage 2 may comprise a component 2A of length
L.sub.M and a coating 2B of length L.sub.C. In an exemplary
embodiment, L.sub.C is about the same length as an exemplary metal
component 2A. In another exemplary embodiment, L.sub.C is between
about 85-95% of the length of metal component 2A so that the
coating covers all but a length of the ends of the metal component
2A that are sufficient to couple the linkage 2 of this exemplary
embodiment in an exemplary block 10/30-70, e.g., L.sub.T. In yet
another exemplary embodiment, L.sub.C is whatever length necessary
to leave about 0.090-0.150 inches of the end of a metal component
2A exposed on either side or both sides of linkage 2, e.g., an
L.sub.T=0.090-0.150. In another exemplary embodiment, coating 2B
may envelop metal component 2A on all sides, as may be shown in
FIG. 16C by an exemplary face coating 2C. In another exemplary
embodiment, where a Lego brick 10/50/60/70 is used for receiving an
exemplary linkage 2 of length L.sub.C, the length L.sub.C may be no
greater than about 110-115% the length of L.sub.M so that the
linkage does not interfere with other structures trying to fit
within Lego brick 10 (e.g., other Lego bricks 10, 50-70, other
exemplary linkages 2). In an exemplary embodiment where L.sub.T is
the length of component 2A on which contours 3a-e, and 3g may be
found, such contours 3a-d, and 3g may be disposed such that enough
contours 3a-e, and 3g can frictionally engage opening 5/6 of an
exemplary block 10/30-70 or the exemplary opening 16 of an
exemplary socket 15. L.sub.C may be a function of L.sub.M, T.sub.C,
D.sub.M, D, L.sub.T, and combinations thereof. In this context,
"function of" refers to any known mathematical operation or series
of operations involving one or more of L.sub.M, T.sub.C, D.sub.M,
D, L.sub.T, and operations involving the same.
[0089] In an exemplary embodiment all lengths L.sub.M and L.sub.C
may be based on the number of studs and/or Lego Drawing Units
("LDU") of exemplary Lego blocks 10, e.g., two stud lengths, three
stud lengths, four stud lengths, etc., as would be understood by a
person of ordinary skill in the art. In an exemplary embodiment,
length L.sub.C and/or L.sub.M may be between about 4 and about 8
LDU in length as measured from the forward-most end of the linkage
2. In this exemplary embodiment, length L.sub.C and/or L.sub.M may
be such as to enable linkage 2 to avoid interference between itself
and other structures traveling through an exemplary block 10. In
yet another exemplary embodiment, length L.sub.C and/or L.sub.M may
be between about 2 and about 16 LDUs in length as measured from the
forward-most end of an exemplary linkage 2, e.g., section 2C/D or
the head/tail 1/0 made up of only component 2A. In still other
exemplary embodiments, length L.sub.C and/or L.sub.M may have the
same LDU lengths as the smallest and/or longest Lego blocks known
to those skilled in the art. L.sub.T may be a length of metal
component 2A sufficient to allow for a UNF Fine Thread #0, 7
threads, 0.010 inch chamfer and a 0.0125 inch thread relief zone
between coating 2B and the most proximal thread 12.
[0090] In an alternative embodiment, as illustrated by FIG. 16B, an
exemplary posable linkage 2 may comprise a component 2A of length
L.sub.M with contoured ends 3a-d/g and/or thread ends 12 and
terminus 11 opposite head/tail 1/0. In this illustrative
embodiment, a coating 2B may substantially cover a metal component
2A over a distance L.sub.C and leave exposed a length L.sub.T for
contouring 3 or threading 12. In an exemplary embodiment where
L.sub.M is a length of component 2A with threading, the types of
thread ends 12 and lengths (L.sub.M, L.sub.C, and L.sub.T) that may
be used for an exemplary linkage 2 may be shown in Table 1 (those
skilled in the art would understand that the value of L.sub.T and
the threading type/number of threads may correspond to one or more
of the length and/or threading of channel 16, 16a-b and channel
threads 18 of an exemplary brick or block 10/30-70 and/or the
length and threading of channels and threads in socket 15/15.sub.1,
including the spacing and length of use of socket structures 15a,
17, and/or 17a):
TABLE-US-00001 TABLE 1 Exemplary Illustrative Embodiments (FIGS.
3A, 3D, Threading 6B, 7B, 7F, 11C, 12C, Type/number 13A-C, 15,
& 16B-C) L.sub.M L.sub.C L.sub.T of threads I 0.625 inches
0.400 inches 0.100 inches UNF #0 II 1.250 inches 1.000 inches 0.100
inches UNF #0 III 2.500 inches 2.200 inches 0.100 inches UNF #0 IV
1.000 inches 0.700 inches 0.150 inches 8 threads V 4.000 inches
3.750 inches 0.120 inches 7 threads VI 8.000 inches 6.000 inches
0.550 inches 12 threads VII 1.250 inches 0.700 inches 0.250 inches
10 threads VIII 0.500 inches 0.300 inches 0.100 inches 6 threads IX
3.000 inches 2.500 inches 0.250 inches UNF #0 X 2/3 inches 1/3
inches 1/6 inches UNF #0
[0091] In the illustrative exemplary embodiments of FIGS. 16B-C, an
exemplary linkage 2 may have threaded sections 12 that are further
from the axis of the linkage 2, e.g., they are located outside the
diameter of component 2A, with or without coating 2B. While
threaded sections 12 may be illustrated in FIG. 16B, contoured
sections 3a-e/g may also be used in place, or used as per the
illustrative embodiment of FIG. 16C, such that one or more of their
individual heights or the average height of all such contours,
extend beyond the non-threaded/non-contoured diameter of component
2A, D.sub.MnT. In an exemplary embodiment, a threaded section 12
may have a height H.sub.T that makes the threaded section 12 have
the same or slightly larger D compared to the central cross-section
of linkage 2 (e.g., linkage 2 with and without coating 2B). In an
exemplary embodiment, the height of threaded section 12, H.sub.T,
may be about 0.0625 inches from an axis running perpendicular to
the cross-section of linkage 2. At this exemplary height, threaded
section 12 may couple a plurality of threaded Lego blocks 10
together, such as those illustrated and described with respect to
FIGS. 7A-F. Alternatively, threaded section 12 may couple a
plurality of threaded non-Lego type blocks 10, e.g., K'nex,
Construx, together.
[0092] In an exemplary embodiment, threaded sections 12 may result
from thread rolling or other such cold rolling machining processes
as described with respect to FIG. 18 and which may are known to
those skilled in the art. In an exemplary embodiment, the ratio of
(H.sub.T+D.sub.MnT) to D is between about 0.80 to about 1.64. In an
alternative exemplary embodiment, the ratio of H.sub.T to D.sub.MnT
is between about 0.05 to about 0.20. Where an exemplary linkage 2
has a plurality of contours 3a-e/g, D.sub.MnT may be calculated by
taking the average cross-section as previously described, and
H.sub.T may be calculated by taking the average of the peaks and
troughs of each of the plurality of contours 3a-e/g as compared to
the D.sub.MnT, where all peaks and troughs above D.sub.MnT to have
positive values and all peaks and troughs below D.sub.MnT to have
negative values.
[0093] In the illustrative exemplary embodiment of FIG. 16C, an
exemplary linkage 2 of diameter D may have a coating 2B over
substantially its entire length L.sub.M so that L.sub.C may
represent the operative length of linkage 2. Those skilled in the
art may appreciate that FIG. 16C may illustrate embodiments of an
exemplary linkage 2 having a metal component 2A covered in a
flexible tube 2B. Alternatively, FIG. 16C may illustrate various
surface features of an exemplary linkage 2, but it should be
understood any of the illustrated features may be found in
isolation of other features or over different distances, depths,
and have different shapes, angles, dimensions, configurations, and
properties, including partial, intermittent, and complete covering
arrangements. For example, an illustrative linkage 2 of FIG. 16C
may comprise contours 3a-e/g and threads 12 as disclosed for
linkages 2 from FIGS. 3A-D, but it may comprise one or more such
features in different forms. For example, an exemplary linkage 2
may have a coating 2B, wherein the coating 2B may have threads 12
at both head 1 and tail 0 of the linkage 2. Alternatively, coating
2B of an exemplary linkage 2 may have only contours 3a-e/g and no
threads along its length L.sub.C. Any of the surface geometries
illustrated by and/or described with respect to FIG. 16C may apply
equally to exemplary linkage coatings, such as coating 2B, of any
other figures, including, but not limited to, FIGS. 3A-D, 16A-B, 5,
11, and 15.
[0094] As further illustrated by FIG. 16C, an exemplary component
2A may have a major diameter D.sub.M and a minor diameter D.sub.m.
For an exemplary component 2A with a minor diameter D.sub.m,
D.sub.m may be dimensioned to engage one or more internal contours
3f of coating/tube 2B. An exemplary contour 3f may allow for better
adherence of coating/tube 2B to component 2A, may allow for greater
resistance to tearing, wearing, disengagement with, or
over-stretching of coating/tube 2B, e.g., in response to flexing or
movement of component 2A. In an exemplary embodiment, an exemplary
coating/tube 2B may be dimensioned, including use of contours 3f,
so as to allow linkage 2 to satisfy Section 9.3.6 Flexure Test of
the June 2010 United States Consumer Product Safety Commission
Laboratory Test Manual for Toy Testing. An exemplary D.sub.m may
also serve to participate in formation of contours on coating/tube
2B during a coating process as discussed with respect to FIG. 18.
In this manner, a component 2A with a particular pattern of D.sub.M
and D.sub.m may be contoured (e.g., contours 3a-d/g, 12) so that
when a coating 2B is applied, an internal contour 3f may be formed
and an external contour 3a-e/g and/or 12 may be formed. As further
illustrated in FIG. 16C, coating contours 3e may be among any of
the coatings 3a-d/f/g/h described herein, including combinations
and patterns of the same.
[0095] As further illustrated in FIG. 16C, an exemplary face
coating 2C may be at the head 1 and/or tail 0 of an exemplary
linkage 2. An exemplary face coating 2C may have the same or lesser
friction than coating/tube 2B. An exemplary face coating 2C/2D may
provide a soft zone or flexible buffer region for an exemplary
metal component 2A to allow such a linkage 2 to satisfy any of the
tests found in section 18 of the June 2010 United States Consumer
Product Safety Commission Laboratory Test Manual for Toy Testing,
in particular all subsections of section 9.2 and 18, in particular,
section 9.2.4 Sharp Point Test, 9.2.5 Sharp Edge Test, and 9.3.6
Flexure Test. While a face coating 2C/2D may be used to satisfy the
aforementioned tests, as disclosed herein, an entirely metal
linkage 2 or a linkage 2 comprising flexible coatings substantially
along its length but with exposed metal faces and/or ends may also
be configured to satisfy the tests of the June 2010 United States
Consumer Product Safety Commission Laboratory Test Manual for Toy
Testing, including Sections 9.2.4, 9.2.5, 9.3.6, and 18. In an
exemplary embodiment, face coating 2C/2D may have a maximum amount
of material at a height of 0.5D and/or 0.5D.sub.M. In another
exemplary embodiment, face coating 2C/2D may have multiple peaks,
valleys, and/or protrusions of various cross sections, e.g.,
circular, rectilinear. Furthermore, the illustrative embodiment of
FIG. 16C may result from extrusion coating a length of component 2A
and then molding its extremes to create a face coating 2C/D using a
heated mold, lathes, presses, or other surface molding techniques
known to those skilled in the art.
[0096] As further illustrated in FIG. 16C, one or more thicknesses
of coating 2B may be found on an exemplary component 2A of an
exemplary linkage 2. In one embodiment, coating 2B may have a
thickness T.sub.C1 measured from an outside contour 3a-e/g and/or
thread 12 to an inside contour 3f. In another embodiment, coating
2B may have a thickness T.sub.C2 measured from a non-contoured
surface of the coating 2B to the most radially proximal surface of
component 2A. In this embodiment, an area of surface of coating 2B
may be considered "non-contoured" if surfaces within the square
area maintain the same perpendicular distance from the axis of
component 2A. In another embodiment, coating 2B may have a
thickness T.sub.C3 measured from a contoured surface 3e of coating
2B to the most-radially proximal surface of component 2A. In
another embodiment, coating 2B may have a face coating 2C of
thickness T.sub.C4 measured from the outer surface of face coating
2C to the closest surface of component 2A. In yet another
embodiment, coating 2B may have a face coating 2D of thickness
T.sub.C5 measured from the furthest end of linkage 2 to the
furthest end of component 2A.
[0097] In an exemplary embodiment, T.sub.C1, T.sub.C2, and T.sub.C3
are substantially equal. In another exemplary embodiment, one or
more of T.sub.C1, T.sub.C12, or T.sub.C3 is no greater than about
0.01 inches to about 0.05 inches, such as, for example, 0.031925
inches. In yet another exemplary embodiment, T.sub.C2 is always
less than T.sub.C1. Alternatively, in another exemplary embodiment,
T.sub.C3 is substantially equal to T.sub.C1. In yet another
exemplary embodiment, T.sub.C3 may be any of the values for
exemplary threads 12 in Table 1. In another embodiment, T.sub.C4
and T.sub.C5 are dimensioned to comply with the June 2010 United
States Consumer Product Safety Commission Laboratory Test Manual
for Toy Testing, including Sections 9.2.4 and 18.
[0098] In another exemplary embodiment, T.sub.C4 is substantially
equal to T.sub.C5. Alternatively, T.sub.C4 may be greater than,
less than, a fraction of, or a multiple of T.sub.C5. In an
exemplary embodiment, T.sub.C1, T.sub.C12, T.sub.C3, T.sub.C4,
T.sub.C5, and combinations thereof may be dimensioned to allow
exemplary linkage 2 to enter one or more openings 5/6 of an
exemplary block 10/30-70 and engage the opening 5/6 sufficiently to
be posed while also being situated therein. In another exemplary
embodiment, L.sub.C does not necessarily equal L.sub.M+T.sub.C4. In
such an exemplary embodiment, coating 2B may have a coating surface
located at L.sub.M-T.sub.C4, in particular, when the ends of
component 2A have their own contours 3f at their axial extrema.
[0099] As may be shown in the illustrative embodiment of FIG. 16D,
an exemplary joint 20 may be shown. As illustrated, a joint 20 can
be shown in cross-section such that an exemplary linkage 2 may be
cut to expose its component 2A and coating sides 2B and an
exemplary block 10 may be cut to expose the cross-section of an
opening 5. While opening 5 has been shown, it is understood as
previously described that any other opening 5/6 or other aperture
or cavity may be contemplated. In the illustrative embodiment of
FIG. 16D, exemplary head/tail 1/0 of an exemplary linkage 2 has
been coupled with block 10 so that an exemplary coating 2B of a
flexible type, such as, for example, an elastomer material,
deflects as it enters opening 5. While head/tail 1/0 may be shown
with a convex surface for an exemplary linkage 2, head/tail 1/0 may
alternatively be any of the aforementioned shapes and surfaces
described, for example, concave, jagged, labyrinthine.
[0100] Accordingly, coating 2B has a first height X.sub.1, which
may be the radial height from the center of linkage 2, the
thickness T.sub.C, or other measurement with a defined reference
point. As coupled via opening 5, an exemplary linkage 2 may have a
junction contour 3h formed in its coating 2B and which may be at a
height X.sub.2. X.sub.2 may be slightly less than the height
X.sub.1 of coating 2B. The portion of linkage 2 that may be coupled
within an exemplary block 10/30-70 may have a coating 2B that is at
a height X.sub.3, which is at least less than the height X.sub.1,
and may, in certain embodiments, be less than the height X.sub.2.
In an exemplary embodiment the ratio X.sub.2/X.sub.1 may be between
about 0.925 and about 0.999. In another exemplary embodiment the
ratio X.sub.3/X.sub.1 may be between about 0.8725 and about 0.99.
In an exemplary embodiment, X.sub.3/X.sub.1 may be between about
0.95 and about 0.90 for both a resilient and flexible coating 2B
that may exert friction forces on the inside of opening 5 of an
exemplary block 10/30-70.
[0101] According to the illustrative embodiment of FIG. 16D, the
portion of an exemplary head/tail 1/0 of an exemplary linkage 2
that contacts the opening 5 of block 10/30-70 may be a length
L.sub.K. In an exemplary embodiment L.sub.K may be less than the
depth of opening 5 of block 10 measured from the outermost edge of
opening 5 to cavity 8 of an exemplary block 10, e.g., 1/4 of the
depth, 1/2 of the depth, or 3/4 of the depth. Alternatively,
L.sub.K may be such that a free length of an exemplary linkage 2
within an exemplary block 10, denoted L.sub.F, does not interfere
with other structures trying to fit within Lego brick 10 (e.g.,
other Lego bricks 10, other exemplary linkages 2). Further
alternatively, L.sub.K may be based on the number of studs and/or
LDU of exemplary Lego blocks 10, e.g., two stud lengths, three stud
lengths, four stud lengths, etc. In an exemplary embodiment, length
L.sub.K may be between about 1 and about 3 LDU in length as
measured from the forward-most end of opening 5. In an exemplary
embodiment, length L.sub.F may be between about 1 and about 2 LDU
in length as measured from the boundary of an exemplary cavity 9
and an exemplary opening 5 of an exemplary block 10/30-70.
Alternatively, L.sub.F may be measured from the surface within an
exemplary block 10/30-70 that either (i) lies in a plane that is
orthogonal to opening 5, or (ii) whose central axis is orthogonal
to the central axis of opening 5.
[0102] With further reference to FIG. 16D, an exemplary linkage 2
may be coupled to an exemplary block 10/30-70 via opening 5 or any
other disclosed aperture by compressing an exemplary elastomeric
coating 2B from a height of X.sub.1 (outside of opening 5), to a
height X.sub.2 (on the border outside or inside of opening 5), to a
height of X.sub.3 (inside of opening 5). In alternative
embodiments, coating 2B may regain some, all, or none of its
original height X.sub.1 once inside cavity 8 of the aforementioned
exemplary block, wherein that cavity height is X.sub.4. An
exemplary internal coating 2B height X.sub.4 may be the height at
any point on coating 2B along L.sub.F. In an exemplary embodiment,
the ratio X.sub.4/X.sub.1 may be between about 0.975 and about
0.999.
[0103] FIG. 16D may be used to illustrate one exemplary concept of
the operation of an exemplary linkage 2 in terms of its activity at
the block opening 5 of an exemplary block, as previously described.
An elastomeric coating 2B may be joined to component 2A as per
coating process 520 as described with respect to FIG. 17. An
exemplary coating 2B may have a juncture 2J with component 2A that
may contain one or more adhesives, welds, stitches, and/or
impregnated material into component 2A, or combinations of the
same. Alternatively, where coating 2B may be a tube, juncture 2J
may be a substantially non-permanent junction between component 2A
and coating 2B, e.g. it may rely on friction or other mechanical
couplings that do not modify the material of the component 2A
and/or the coating 2B.
[0104] As will be further discussed, an exemplary linkage 2 may be
coated with coating 2B about substantially its entire length first,
stripped at its ends to expose underlying metal component 2A
second, and thread rolled and/or subject to any other known
thread-forming and cold rolling technique known to those skilled in
the art and shown and described with respect to FIG. 17, processes
520, 530, and 540 to form threads or contours on the exposed metal
sections of component 2A on length L.sub.T. However, in an
alternative exemplary embodiment, the aforementioned steps may be
done in reverse order depending on the instrumentation and
capabilities to coat thread-rolled and/or cold-rolled linkage metal
component 2A of an exemplary linkage 2 with coating 2B so as not to
substantially interfere with the prior-formed threading 12 of
linkage 2. In an exemplary embodiment, the threaded metal component
2A may be screwed into chucks (not shown) and then coated with
coating 2B so that unscrewing the coated, thread-rolled component
2A will leave un-coated the threads 12 formed prior to chuck
application. While the foregoing embodiment may rely on a chuck to
prevent coating of exemplary linkage 2 threads 12, those skilled in
the manufacturing art may recognize other techniques and
arrangements to avoid coating the threads 12 of an exemplary
linkage 2.
[0105] FIG. 17 is an illustrative embodiment of a process 500 of
manufacturing an exemplary linkage 2 for use with an exemplary
block 10/30-70, and/or linkage-block joint 20 as illustrated and/or
described by way of disclosures herein and all interrelated
disclosures. During an exemplary drawing step 510, an amount of
material, such as a metal, may be extruded, cut, folded,
3D-printed, sintered, machined, or otherwise formed. Those skilled
in the material fabrication arts may understand the various
processes involved in the formation of metal wires, such as, for
example aluminum armature wire, copper wires, brass wire, and
alloys and galvanized variants of the same. In another aspect of
this exemplary embodiment, an exemplary drawing step 510 may
include unwinding a roll or packing of previously-formed material,
such as, for example, a wound length of metal wire. An exemplary
drawing step 510 may include extruders, cams, pulleys, drive
wheels, calendars, rollers, and other equivalent structures used by
those skilled in the manufacturing art to move material from one
location to another in a controllable fashion. While not as
efficient, manual drawing of material for an exemplary process 500
may also be contemplated. The material drawn in drawing step 510
may be the entire linkage 2 or a component of linkage 2 (e.g.,
component 2A, component 2B, or component 2A and 2B alone or in
combination).
[0106] Where a coating 2B may be applied to a component 2A via
decision step 515, an exemplary coating step 520 may involve
placing a coating 2B on a portion of or substantially about the
entirety of a length of the drawn material, including placing an
intermittent or discontinuous pattern about the material length. An
exemplary coating step 520 may rely on spraying the material about
the component 2A, co-extruding the coating about the length of
material as it is passed through the same extruder, dipping the
material in a bath or mold of material and then cooled, and/or
slipping the material into a coating sleeve, jacket, tube, or other
integrated construct that can envelop the material. In an exemplary
embodiment, the coating 2B is a flexible material, such as fabric,
rubber, and/or elastomer. In a further exemplary embodiment, the
coating 2B is silicone, rubber, or combinations/isomers thereof. In
a yet further exemplary embodiment, the coating 2B is co-extruded
onto the length of wire (L.sub.M) substantially about its entire
length, such as, for example, L.sub.C. An exemplary coating step
520 may result in one or more of the various linkage 2 embodiments
illustrated and disclosed with respect to FIGS. 1-16, and further
in particular, FIGS. 16A-D and 18A-D.
[0107] As described, an exemplary process 500 may involve certain
decision steps, such as those exemplified in decision steps 515,
525, and 527. Decision steps may be undertaken manually or through
use of automated methods, such as data acquisition (DAQ) equipment
arranged about the process components that undertake the steps of
process 500. For example, an exemplary coating decision 515 may
involve a pre-programmed computer algorithm that may take inputs
from sensors installed in an exemplary process 500 assembly line,
and decide whether a coating 2B need be applied to an incoming
component. According to an exemplary embodiment, a laser
measurement tool known to those skilled in the art may be used to
measure the distance from a fixed distance to the surface of a
constituent of an exemplary linkage 2. Thus, if the constituent,
such as component 2A, is at a larger distance than a component 2A
that is coated with 2B, an exemplary decision step 515 may involve
sending the distance measured to an algorithm that determines
whether to direct the component 2A to be coated, e.g., use of
"if-than-else" statements, lookup functions such as those used in
Excel Visual Basic for Applications ("VBA") which includes, but is
not limited to the following exemplary functions and/or algorithms:
hlookup, vlookup, getpivotdata, lookup, and match. In a more
particular embodiment, an exemplary algorithm may be written in any
language for operation by a computer, such as those known to
persons skilled in the programming arts (e.g., C+, C++, Java,
Sequel, Perl, HTML, Assembly, Visual Basic, Q Basic, and others
identified via the following website as of the date of these
disclosures--https://en.wikipedia.org/wiki/List_of_programming_languages)-
. Alternatively, those skilled in the art can control performance
of an exemplary process 500 as illustratively shown in FIG. 18 via
Simulink, Matlab, or other known control systems.
[0108] In an exemplary algorithmic form of decision step 525, the
measurement of an analog or digital device may be retrieved, e.g,
the signal representative of the horizontal measurement between a
laser and a component 2A (referred to herein as step 525(i)),
compared to a known quantity, e.g., the horizontal measure of the
laser origin to the linkage 2 component 2A plus the thickness of an
exemplary coating 2B (which may be adjusted by a user) (referred to
herein as step 525(ii)), and take a specific action in the process
500 based on the comparison (referred to herein as step
525(iii)).
[0109] For example, an exemplary decision step 525(ii) may
determine whether the measurement data received is less than the
distance from the measurement device to linkage 2 component 2A, and
if so, instruct the processor of the computer to send a signal
(analog or digital) to the controllers to progress the linkage 2 to
the next step of an exemplary process 500. Alternatively in the
aforementioned exemplary embodiment, decision step 525(ii) may
yield a value greater than the horizontal measurement plus the
thickness 2B, in which case the activity portion of the algorithmic
decision step 525, namely, 525(iii), may involve the delivery of a
signal controlling coating, rotors, and actuators to move linkage 2
through a coating device, such as a polymer/elastomer extruder, in
order to begin the exemplary coating 520 step of an exemplary
process 500. In an even more particular embodiment, when a laser
sensor is 0.5 inches away from an exemplary component 2A of
circular cross section and measures a distance equal to or greater
than about 0.53175 inches, then the sensor signals to the remainder
of the systems in process 500 to put the coating 2B on the
component 2A.
[0110] In an exemplary process 500, decision step 525 may include
analyzing whether the coating 2B applied to an exemplary component
2A in step 520 results in an L.sub.C that is greater than or equal
to L.sub.M. An exemplary decision step 525 may be determined using
laser scanners, optical sensors (e.g., optical LEDs to determine
presence of coating via light reflected off the coating), point and
roller probes to determine presence of plastic or elastomer up and
down the length of linkage 2, or manual inspection.
[0111] In an exemplary process 500, decision step 527 may include a
pre-set determination of a contoured component 2A in addition to or
exclusive of a contoured coating 2B. Thus, an exemplary decision
step 527 may be algorithmic to the extent a contoured component 2A
may be required in certain amounts based on the number of contoured
coatings 2B, based on a pattern of contoured component 2A
manufacture, or based on a demanded amount delivered to the
algorithm via online or other means as a number of units. An
exemplary algorithmic decision step 527 may decide whether to
contour a component 2A of linkage 2 based on a voltage or other
digital input ("1" to signal contour component 2A, "0" to signal do
not contour component 2A). As a result, in an exemplary process 500
in which component 2A of linkage 2 is to be contoured, the coating
2B may be removed from linkage 2 during an exemplary stripping
process 540. If contouring of component 2A is not required, the
linkage 2 may be scheduled for cutting as per an exemplary cutting
process 530.
[0112] All decision steps disclosed for an exemplary process 500
may be represented in algorithmic form as would be understood by a
person of ordinary skill in the programming and manufacturing arts.
Alternatively, the algorithms for an exemplary decision step
515/525/527 may be a control feed-back loop that uses the output of
an exemplary process 500 at any stage of the process to determine
what decision is to be made in the step. For example, an input into
any one of the algorithmic versions of decision steps 515/525/527
may be the amount of contoured linkages 2 with coatings 2B, which
triggers the decision steps individually or together to balance
that amount with an equal number of non-contoured linkages 2, with
and without coating 2B.
[0113] An exemplary cutting step 530 may involve manual,
semi-automatic, or automated cutting processes to shorten a length
of material, whether coated or not coated as per coating step 520.
An exemplary manual cutting step 530 may include use of lathes,
saws, lasers, blades, or other mechanisms known to those skilled in
the manufacturing arts sufficient to separate lengths of material
from other lengths of material. In an exemplary semi-automatic
cutting process 530, linkage 2, whether coated or not coated as per
coating step 520, may be manually held while acted upon by an
automatic cutting machine of the type known to those skilled in the
art, such as, for example, machines and mechanisms manufactured by
Schleuniger Inc. of Thun, Switzerland, such as, for example, the
EcoStrip series of machinery, or the EcoStrip 9320 automatic cut
and strip machine. Other like machinery and mechanisms suitable for
use in an exemplary cutting process 530 are also within the
knowledge of those skilled in the manufacturing arts.
[0114] Alternatively, linkage 2, whether coated or not, may be
controllably cut about its length via cams, rollers, conveyor
belts, and other automated apparatus known to those in the
manufacturing arts. An exemplary cutting process 530 may utilize
the automated cutting system provided by machines and mechanisms
manufactured by Schleuniger Inc. of Thun, Switzerland, such as, for
example, the EcoStrip series of machinery, e.g., the EcoStrip 9320
automatic cut and strip machine.
[0115] An exemplary stripping step 540 may involve manual,
semi-automatic, or automated stripping process. In one embodiment,
an exemplary stripping step 540 may be used to shorten the amount
of coating 2B, e.g., L.sub.C or T.sub.C, on an exemplary component
2A of linkage 2. Alternatively, an exemplary stripping step 540 may
be used to remove a portion of an end of linkage 2 to expose
component 2A, such as may be seen in one variant of the
illustrative embodiment of FIG. 3A where a coating 2B may be shown
as the threads 12 and the exposed end of component 2A as terminus
11. In an exemplary embodiment, an automatic cutting machine of the
type known to those skilled in the art, such as, for example,
machines and mechanisms manufactured by Schleuniger Inc. of Thun,
Switzerland, such as, for example, the EcoStrip series of
machinery, e.g., the EcoStrip 9320 automatic cut and strip machine.
In another exemplary embodiment, an exemplary cutting process 530
and an exemplary stripping process 540 may take place before or
after the other, or directly after one another, as may be the case
if using an EcoStrip series machine from Schleuniger Inc., as
previously stated. Other like machinery and mechanisms suitable for
the aforementioned stripping process 540 are also within the
knowledge of those skilled in the manufacturing arts.
[0116] An exemplary channeling process 550 may be used to redirect
cut, stripped, or otherwise processed product to either a
contouring process, a collecting process, and/or a packaging
process, such as, for example, the exemplary contouring process
(560), collecting process (570), or packaging process (590)
illustrated and described herein. An exemplary channeling process
550 may take advantage of any form of communication mechanism for
physical products known to those in the industrial arts, for
example, chutes, funnels, conveyors, cams, rollers, pulleys, lifts,
robotic arms, magnets, pipes, tubes, vacuum/suction mechanisms, or
equivalent means of moving product in an assembly line or
production facility.
[0117] An exemplary channeling process 560 may be controlled by way
of motion detectors, e.g., laser, pressure, vibratory, or other
contact and/or non-contact sensors, or by use of mechanical
components whose revolution may either permit open and closed
access to travel (e.g., gears, cams, structures with intermittent
openings in a path of rotation), or other mechanical passage
controls (e.g., spring-loaded doors, walls, or panels that return
to closed or open state after passage of a product, sifters).
[0118] In any of the aforementioned exemplary embodiments, an
exemplary channeling process 550 may be controlled via feedback
loops and other digital or analytical tools to monitor product
output and/or extent of production, e.g., a computer, mobile
device, video camera, analog recorder, or mobile application
running on one or more of a computer or mobile device, such as a
smartphone. Indicia of product production may be based on product
passage over sensors, passage controllers, or by scanners
electronically trained to detect the final products by material
composition, color, length, or other mechanical, chemical,
electrical, and/or other material characteristics.
[0119] For example, an exemplary channeling process 550 may
incorporate a motion sensor known to those skilled in the art to
detect when a product passes along its length and from that data
provide the digital or analytical tool(s) one or more of: product
speed of passage and number of completed product, for example. In
one aspect of the foregoing example, product speed may be sent to a
mobile device via text message or other such communication to alert
an operator to progress of a job. In another aspect of the
foregoing example, product number can be recorded for calculating
job efficiency, cost, material, and production modifications. Those
skilled in the industrial arts may be aware of many metrics,
formulae, and equations by which to derive indicia of production
efficiency, progress, quality control, output, resource usage,
and/or forecasting.
[0120] In another example, an exemplary channeling process 550 may
incorporate an assembly of magnet and pressure and/or motion sensor
known to those skilled in the art, which may be used to attract a
product with a posable metal linkage 2 so that it contacts the
pressure or motion sensor. In an aspect of this exemplary
channeling process 550, the product can be identified as having a
sufficient degree of coating T.sub.C for an exemplary posable metal
linkage 2 so as to still be attracted by the magnet. In one
additional aspect, the speed and pressure of the product may serve
as factors to identify whether the product has been adequately
coated with material 2B, is not overweight, or is sufficiently
robust for end use.
[0121] An exemplary contouring process 560 may involve a die, tap,
lathe, mold, threaded die, laser, pressured water jet, heat, steam,
or other work or machining station known to those skilled in the
art on which a linkage 2 may be given contours 3/3a-h/11/12 on or
in its surface(s). A linkage 2 may bypass any of the prior
processes 510-550 and go directly to contouring process 560,
depending on needs. For example, a 3D printing enabled process 500
may not require any material be coated (process 520) or cut
(process 530), but may be formed in contouring process 560 which in
this exemplary embodiment is exemplified by a 3D printing system,
such as those described herein.
[0122] In an exemplary embodiment where a product goes through
either one or more of processes 510-550, an exemplary contouring
process 560 comprises receiving the linkage 2 and subjecting it to
roll threading or other form of cold rolling process(es) known to
those skilled in the manufacturing arts. According to this
exemplary embodiment, a product, such as the exemplary product
embodiments illustratively disclosed and described with respect to
FIGS. 16A-D, may be formed by such a thread rolling process 560.
Equivalents of the illustrative embodiments of FIGS. 16A-D may also
be formed by an exemplary thread rolling process 560. In another
aspect of this exemplary embodiment, an exemplary thread rolling
process 560 may be configured to provide threads 12 on a linkage 2
within and about the ranges and/or equivalent ranges described and
disclosed with respect to Table 1.
[0123] In an exemplary contouring process 560, a product may be
acted upon by other types of grinding, cutting, sintering, welding,
cold forming, and/or machining known to those skilled in the art to
create contours 3/3a-h/11/12 as may be illustratively shown by
FIGS. 3A-D, 4A-D, 4G, 5, 6B, 7B, 7F, 9A-B, 10B-C, 11B-C, 12C,
13A-C, 14D, 15, 16A-D, their related and interrelated disclosures,
and any and all permutations, equivalents, and combinations
thereof. For example, a die may be used to cold roll one or more of
the contours 3/3a-h/11/12 detailed in the aforementioned figures
and related and interrelated disclosures. In another example, a
sintering, lathe, laser cutter, CNC, or other material removal
manufacturing process known to those skilled in the manufacturing
arts may be used to create one or more of the contours 3/3a-h/11/12
detailed in the aforementioned figures and related and interrelated
disclosures. In one embodiment, FIG. 3D may illustrate an exemplary
contoured linkage 2 made of one material or an exemplary linkage 2
having an intermittent coating 2B (denoted as 3a) and one or more
exposed portions of component 2A (denoted as 3). In another
embodiment, FIG. 3A may illustrate an exemplary contoured linkage 2
made of one material or an exemplary linkage 2 having an
intermittent coating 2B (denoted as 12) and one or more exposed
portions of component 2A (e.g., terminus 11).
[0124] An exemplary collecting process 570 may involve any
automated, manual, or combinations thereof whereby posable metal
linkages 2 may be grouped, coupled, attached to, and/or otherwise
oriented with one or more types of blocks disclosed herein, such,
as for example blocks 10/30-70, exemplary blocks 10 of FIGS. 7A-E
and 15, exemplary blocks 50 of FIGS. 7F and 15, exemplary block 60
of FIG. 12A, exemplary block 70 of FIG. 14C and/or blocks
30/40/50/60/70 manufactured by one or more of the processes herein
described. An exemplary hybrid brick 50 may be the brick provided
for an exemplary collecting process 570. An exemplary collecting
process 570 may include funneling linkages 2 to repositories (e.g.,
buckets, bins, wells, and/or enclosures) that are also the
repositories of a particular brick 10/30-70 from a similar
funneling step. It may be possible to include an aspect of, part
of, or a different aspect or part of the channeling process 550
described as part of the collecting process. Following collection
in step 570, an exemplary packaging process 580 may be
undertaken.
[0125] In an exemplary embodiment of the packaging process 580 of
the exemplary process 500 illustratively set forth by FIG. 17, a
manual or automatic packaging scheme may be utilized to place
linkages 2, one or more types of brick 10/30-70, or combinations
thereof into preformed boxes, bags, sealable bags, plastic and
cardboard combinations, blisters, or other types of containers.
Alternatively, an exemplary packaging process 580 may include
combining an exemplary linkage 2 with one or more of the blocks
collected previously as they would be assembled for use, e.g.,
placing a head 1 or tail 0 of a linkage 2 within an opening 5 of an
exemplary block 10/30-70 to form a joint 20. In other words, an
exemplary packaging process 580 may involve packaging an exemplary
joint 20 for end use by the consumer to reduce the number of loose
parts in the packaging, e.g., box or bag.
[0126] Furthermore, an exemplary packaging process 580 may also
involve providing instructions to the end user or customer for use
of linkage 2 or joint 20 with one or more bricks 10/30-70 or other
Lego-like or non-Lego-like blocks incorporating such bricks or
others. Such instruction provision may be via printed matter, such
as instruction manuals, or through non-print media, e.g., audio or
digital means, such as television, radio, text messages, voicemail,
email, websites, online video, downloads (e.g., PDF, word
documents, .txt files, mp3/mpeg files, power point files), social
media, or other digital distribution networks and platforms known
to those skilled in the marketing arts.
[0127] Another exemplary embodiment of posability may be seen with
respect to FIGS. 18A-D. In the illustrative embodiment of FIG. 18A,
an exemplary linkage 2 having a component 2A, which may be made out
of a flexible metal, and a coating 2B, such as, for example, an
elastomer or flexible plastic coating, may be coupled to an
exemplary block or blocks 10/30-70 via an opening 5. Block or
blocks 10/30-70 may be further coupled, either removably or
integrally with block or blocks 100/200, which may be the same as
blocks 10/30-70, a block described herein, or any conventional
block in the prior art.
[0128] At the juncture between linkage 2 and opening 5, an
exemplary metal component 2A of an exemplary linkage 2 may be found
along a distance L.sub.K circumscribed by opening 5 and a distance
L.sub.F beyond the walls of opening 5 and/or found in an exemplary
cavity 9 of an exemplary block or blocks 10/30-70. As previously
described, component 2A, which may be made of a flexible metal, may
be located only along length L.sub.K while a coating thickness 2C
may be found along a length L.sub.F. Alternatively, component 2A
may be located along L.sub.K and L.sub.F. The ratio R of L.sub.F to
L.sub.K may be less than about 1.0, and in an alternative
embodiment is no more than about 0.75. Depending on the size and
configuration of opening 5 and block or blocks 10/30-70, ratio R
may be any value that provides the benefits and advantages
described herein. In another embodiment, L.sub.F may be a length
that is about equal to the thickness T.sub.C4 of linkage section
2C. In another embodiment, L.sub.F may be a length that is about
equal to the thickness T.sub.C5 of linkage section 2D. The person
of ordinary skill in the art, by reviewing the interrelated
embodiments of FIGS. 16A-D and 18A-D, will understand numerous
interrelationships between L.sub.C, L.sub.M, L.sub.F, L.sub.K,
T.sub.C4, and/or T.sub.C5 that may be understood from the
disclosures herein. In an exemplary embodiment, the person skilled
in the art would understand the benefits of maintaining some length
of component 2A within opening 5 of block or blocks 10/30-70 to
increase friction and/or contact forces between coating 2B and the
surface(s) of opening 5 of block or blocks 10/30-70.
[0129] With further reference to the illustrative embodiments of
FIGS. 18A-D, an exemplary linkage 2 may be coupled to exemplary
block(s) or brick(s) 10/30-70, such as, for example Lego.RTM.
blocks, Lego-like blocks, hybrid blocks, and/or 3D printed blocks,
which may themselves be connected to or be integral with
blocks/bricks 100/200, such as Lego.RTM. blocks and non-Lego.RTM.
blocks known to those skilled in the art. An exemplary linkage 2
may enter opening 5 of block(s) and/or brick(s) 10/30-70 along the
x-axis. The plane tangent to the surface of block(s) and/or
brick(s) 10/30-70 that intersects an exemplary linkage 2 may be
perpendicular to the central-most axis of component 2A. At this
juncture, the x-, y-, and z-axes for the intersection of the
central-most axis of linkage 2 with block(s) and/or brick(s)
10/30-70, which together form joint 20, may be said to have their
origins located there. However, persons of skill in the art may
determine other locations along an exemplary linkage 2 and/or
components 2A and 2B, or exemplary block(s) and/or brick(s)
10/30-70 that may serve as origins for the x-, y-, and z-axes, see,
e.g., FIG. 2 and FIG. 15.
[0130] Referring to the illustrative embodiment of FIG. 18A, the
component 2A of an exemplary linkage 2 may extend from opening 5
substantially along the x-axis while coating 2B may or may not
extend from opening 5 substantially along the x-axis due to
different contours 3/3a-h in coating 2B, intermittent application
of coating 2B on component 2A, and/or other configurations of
coating 2B. However, in another exemplary embodiment, coating 2B
may extend substantially along the same axes as component 2A,
although it may not completely cover component 2A of an exemplary
linkage 2. Furthermore, while coating 2B may extend along
substantially the same axes as component 2A (e.g., the x-axis), an
exemplary coating 2B may or may not extend from the same points as
component 2A (e.g., only component 2A may be found along length
L.sub.F, while component 2B only begins to exist along length
L.sub.K, as may be the case for an exemplary linkage illustratively
disclosed in FIG. 16B).
[0131] Referring to the illustrative embodiment of FIG. 18B, an
exemplary linkage 2 may extend along the x-axis from opening 5 and
then may be bent along the z-axis so that its cross-section is
visible. While a portion of an exemplary linkage 2 may be posed in
this manner, FIG. 18B may show an entire exemplary linkage 2, which
has its head 1 covered by end coating 2C within block(s) or
brick(s) 10/30-70 and its tail portion uncoated so as to leave
component 2A exposed.
[0132] In use, an exemplary linkage 2 may be bent upon application
of a user force, e.g., a positioning force that results from a user
moving either the linkage 2 and/or a brick or block
10/30-70/100/200 coupled to the linkage 2, and is not one that
results exclusively from gravity acting on the linkage 2 and/or the
brick or block 10/30-70/100/200 coupled thereto). Such a
positioning force may cause an exemplary linkage 2 to have a pose
or conformation p. In an exemplary embodiment, p may comprise an
"elbow" bend (which may be at a substantially right angle) or other
arc-like bend. In an exemplary joint 20, there is minimal to no
curvature .rho. along length L.sub.K, although at least some
curvature .rho. may be present along an exemplary linkage 2 (with
or without coating 2B) at the outside facing end of opening 5
and/or at position X.sub.2. An exemplary curvature .rho. may be one
or more curved portions of an exemplary linkage 2, and not
necessarily just the portion of exemplary linkage 2 at opening
5.
[0133] Referring to the illustrative embodiment of FIG. 18C, an
exemplary linkage 2 may extend from exemplary block(s) or brick(s)
10/30-70 along the x-axis and then be bent by a user in the y-
and/or z-directions so as to have a pose or conformation p. As also
illustratively shown, a portion of component 2A and the component
2's thickness T.sub.C4 of end covering 2C may together cover a
distance of length L.sub.F. The distance L.sub.K illustrated may
only relate to a portion of linkage 2 whose head 1 may be too long
to fit within opening 5 of the particular block(s) or bricks(s).
However, an exemplary linkage 2 may be configured so that the
friction forces from opening 5 resulting from compression of a
flexible covering 2B against a metal component 2A each serves to
securely anchor exemplary linkage 2 within opening 5.
[0134] As illustrated in FIG. 18C, an exemplary linkage 2 may be
bent by a user force into one or more conformations in positive and
negative x-, y- and/or z-axis directions, as has been previously
described. In any one of the exemplary conformations, including
those illustratively disclosed with respect to FIGS. 18C-D, an
exemplary linkage 2 may substantially maintain its pose .rho. over
a period of time. In an exemplary embodiment, .rho. may have an
origin at opening 5 (as shown from the origin of the x-, y-, and
z-axes) and may triangulate with the endpoint of component 2A of an
exemplary linkage 2 that is part of length L.sub.K inside
brick/block 10/30-70 (point Q), the outer-most edge of opening 5
that is parallel to the y/z axes (point R), and all points along
the length of .rho. (shown in dashed and dotted line in FIGS.
18C-D) (point(s) S).
[0135] In an exemplary embodiment of posability, a posability
triangle ("T") may have angles .alpha., .beta., and .gamma. between
lengths QS and RS, RS and RQ, and RQ and QS, respectively. In an
exemplary embodiment .alpha. is always an acute angle between QS
and RS, while .beta. and .gamma. may be any angle between RS and RQ
and RQ and QS, respectively. In another exemplary embodiment, only
when portions of an exemplary linkage 2 in .rho. overlap themselves
may .beta. and .gamma. be substantially 90 degrees. For certain
lengths of exemplary linkage 2, only .beta. may be substantially 90
degrees for one triangle T among all triangles T for a given .rho..
For certain lengths of exemplary linkage 2, .beta. and .gamma. may
be substantially 90 degrees for a plurality of triangles T among
all triangles T for a given .rho..
[0136] In another exemplary embodiment, triangle T may have
coordinates on the x-, y-, and z-axes. In another exemplary
embodiment, triangle T may have coordinates on the x-, and only one
of the y-, and z-axes. In another exemplary embodiment, QR may be
the x-axis length of triangle T or T.sub.X, which may be
substantially equal to the length of component 2A along length
L.sub.K. In yet another exemplary embodiment, QR and/or T.sub.X
lies substantially on the central axis of component 2A. In yet
another exemplary embodiment, QR and/or T.sub.X lies substantially
on the central axis of an exemplary linkage 2.
[0137] An exemplary posability of an exemplary linkage 2 may be
contingent on the section modulus of plasticity and/or the area
moment of inertia. In an exemplary embodiment, an exemplary linkage
2 may be configured so that its section modulus of plasticity (Z)
may be defined by Equation 1:
Z p = ( D M - AVG + 2 T C - AVG ) 3 6 Equation 1 ##EQU00001##
[0138] Where D.sub.M-AVG may be the average of all D.sub.m and
D.sub.M for component 2A about L.sub.M plus L.sub.T (to the extent
component 2A has such contoured ends) and T.sub.C-AVG may be the
average of all T.sub.C1, T.sub.C2, T.sub.C3, T.sub.C4, and T.sub.C5
for covering 2B about L.sub.C. In one embodiment, a posable linkage
2 with component 2A and 2B may have a Z.sub.p less than about
1.4000. In another embodiment, posable linkage 2 may have a Z.sub.p
less than about 0.58333.
[0139] In another exemplary embodiment of posability, an exemplary
linkage 2 may be configured so that the area moment of inertia
("I") for component 2A is less than that for covering 2B. Equations
2 and 3 provide an exemplary calculation for I for a wire-like
component 2A (I.sub.M) and a tubular covering 2B (I.sub.C),
respectively:
I M = .pi. ( D M - AVG ) 4 64 Equation 2 I C = .pi. ( D M - AVG + 2
T C - AVG ) 4 - ( D M - AVG ) 4 64 Equation 3 ##EQU00002##
[0140] In one embodiment, the smaller the area moment of inertia
for an exemplary linkage 2, the greater the posability of the
exemplary linkage 2. In an exemplary embodiment of posability,
I.sub.M<I.sub.C. In an alternative embodiment of posability,
I.sub.M may be less than about 4.9.times.10.sup.-6 in.sup.4 and, in
another alternative embodiment, I.sub.M may be less than or equal
to about 7.4.times.10.sup.-7 in.sup.4. In accordance with these and
other exemplary embodiments, I.sub.C for an exemplary linkage 2 may
be less than about 2.821.times.10.sup.-5 in.sup.4. In an exemplary
embodiment, the ratio of I.sub.C/I.sub.M for an exemplary posable
linkage 2 may be greater than about 1 but less than about 50.
[0141] As a result of being inserted into an exemplary block
10/30-70 via opening 5, an exemplary linkage 2 may have a coating
2B that may exert the following restoring force (F.sub.R) against
opening 5 of one or more of the exemplary blocks and/or their
hybrids described by, for example, Equation 4:
F.sub.R=AE[(X.sub.2-X.sub.1)/X.sub.1] Equation 4
[0142] Where A is the area of an exemplary coating 2B within length
L.sub.K. An exemplary A is equal to the product of the coating 2B
thickness T.sub.C, length L.sub.K, and the product of the number pi
(.pi.) and linkage 2 diameter D. Alternatively, A may be equal to
the product of
0 L K D - D M , ##EQU00003##
length L.sub.K, and .pi.D. Further alternatively, F.sub.R and A may
be the derivative of the force and/or area over length L.sub.K. In
a further alternative embodiment, A may be derived from any other
formulae known to those skilled in the art for determining the area
of coating 2B within length L.sub.K. E is the modulus of elasticity
of an exemplary coating 2B. The restoring force F.sub.R may
represent the force exerted by the compressed portions of coating
2B on the inside surface of an exemplary opening 5.
[0143] As a result of being inserted into an exemplary block
10/30-70 via opening 5, the exemplary length L.sub.K of an
exemplary linkage 2 head/tail 1/0 may be held therein at least by a
friction force F.sub.F exerted against the coating 2B according to,
for example, Equation 5:
F.sub.F=(F.sub.R)(.mu.) Equation 5
[0144] Where F.sub.R is the restoration force for a deflected
coating 2B and .mu. is the coefficient of friction for the opening
5 of an exemplary block 10/30-70. Thus, the dimensioning of an
exemplary coating 2B vis-a-vis opening 5 may allow for greater
frictional forces to retain an exemplary linkage 2 within an
exemplary block 10/30-70. The friction forces F.sub.F may be
increased by the rigid attachment of coating 2B to an exemplary
metal component 2A. In embodiments where blocks 10/30-70 are made
of plastic, such as ABS or PLA plastic, an exemplary linkage 2 with
a metal wire component 2A having a coating 2B adhered thereto may
take greater advantage of the restoring forces F.sub.R generated as
a result of coating 2B deflecting in response to insertion within
such blocks 10/30-70. Application of Equation 2 may be made to
determine the friction force of coating 2B (F.sub.Fc) generated by
the resistance forces of the opening 5 of the exemplary block
10/30-70 on coating 2B, where .mu. is that for the material of
coating 2B. Use of an exemplary coating 2B in conjunction with
component 2A may make for a more robust retention of an exemplary
linkage 2 within the opening 5 of an exemplary block 10/30-70 and
blocks incorporating the same.
[0145] In a further exemplary embodiment, as illustratively shown
in FIGS. 19A-D, an exemplary linkage 2 of the type disclosed may be
an integrated linkage 2E that may be integrally formed with a
Lego-like block or brick 80 and/or be a welded linkage 2F that may
be mechanically/chemically attached to a block/brick 90.
Block/brick 80/90 may be a form of any block or brick 10/30-70,
coupled or integrally formed with one of blocks 100/200, and/or may
be a form of any other block or brick disclosed or known to those
skilled in the art. For example, block 80 may be made out of a
plastic or other material that can be integrated with the material
comprising linkage 2E. In an exemplary embodiment, block 80 may be
made of ABS plastic while linkage 2E may be made of a flexible
metallic component 2A covered by a rubber coating 2B that is
integrally molded to block 80. In an exemplary embodiment, the
material comprising linkage 2E may be formed first and then
integrated with the mold or fabrication tooling while making block
80 so that linkage 2E can be embedded within block 80 as it is
formed and/or be "captured" by the material making up block 80 so
as to form one component. An exemplary linkage 2E may be
pre-treated to couple to a block 80 by increasing the surface area
on the integration end of the linkage 2E, e.g., increasing grooves,
gnarling, contouring, cold rolling, and other surface area
increases known to those skilled in the art. An exemplary
integration end of linkage 2E may be one or more of the head 1 or
tail 0 sections of disclosed linkages 2.
[0146] In an alternative embodiment, FIGS. 19A and 19C illustrate
an exemplary weld linkage 2F that may be adhered to or otherwise
held by Lego-like block or brick 90 by way of glues, pressure
welding, vibration welding, sintering, soldering, or plastic
welding. The adhesion location for linkage 2F to Lego-like brick 90
may be at joinder section 92, which may be intermittent or
substantially continuous along the length of linkage 2F bounded by
Lego-like brick 90. In exemplary embodiments, linkages 2E and 2F,
Lego-like blocks 80 and 90, component 2A, and coating 2B may be
interchanged with, interrelated to, combined with, used as an
alternative to, and/or modified by any of the disclosures of toy
linkages and related systems herein.
[0147] An exemplary integrated linkage 2E may be embedded in block
80 as shown in FIG. 19B. As described with respect to FIGS. 16A-D,
an exemplary integrated linkage 2E may have an overall diameter D
that may be substantially the same as or less than the thickness of
block 80, T.sub.BR. Alternatively, an exemplary linkage 2E may have
a component 2A of diameter D.sub.M that is integrated with block
80. According to this exemplary embodiment, component 2A may have
one section that may be integrated with block 80 and a remainder
section that is not integrated with block 80, the "free" section,
that may be component 2A in isolation, component 2A with covering
2B, and any form of other linkage 2 forms, components, coverings,
and interrelationships disclosed. For example, an exemplary linkage
2E may be integrated with block 80 over a length equivalent to
length (i) L.sub.K, (ii) L.sub.K+L.sub.F, and/or (iii) L.sub.T.
Alternatively, an exemplary linkage 2E may have a threads 12 or
contours 3a-h at its head 1 to allow for better integration with
block 80. In another embodiment, block 80 may be a more elaborate
form of face covering 2C/D applied to a coated linkage 2.
[0148] An exemplary welded linkage 2F may be coupled to block 90 as
shown in FIG. 19C. As described with respect to FIG. 16A-D, an
exemplary welded linkage 2E may have an overall diameter D that may
be substantially the same as, greater than, or less than the
thickness of block 90, T.sub.BR. In an exemplary embodiment, block
90 may have a repository .PHI. in its surface for a welded linkage
2F such that a portion of linkage 2F diameter D intersects block 90
thickness T.sub.BR. In another exemplary embodiment, block 90
joinder sections 92 may be formed so that the diameter D of linkage
2F may be interconnected with a surface .GAMMA. or in the thickness
T.sub.BR of block 90. An exemplary diameter D of linkage 2F or
surface .GAMMA. of block 90 may be treated to increase its surface
area to permit an exemplary joinder 92 between both. While joinder
92 may be shown filling in the entire area between diameter D and
block 90 surface .GAMMA., this may not necessarily be the case, and
air gaps, channels, and cavities may be present without affecting
the goal. As previously described, joinder 92 may be comprised of a
bonding agent or glue, a melted plastic or epoxy, a solder, a
stitch, a staple, a vibration weld, pressure weld, sintered edge,
and/or other weld form known to those skilled in the art. In an
exemplary embodiment where linkage 2F may be a coated linkage
having a cover 2B of thickness T.sub.C, the thickness T.sub.C may
be smaller at joinder sections 92 than elsewhere on linkage 2F to
account for chemical/mechanical augmentations to allow coupling of
linkage 2F to brick 90. Alternatively, an uncoated section of
linkage 2F having threads 12 and/or contours 3a-h may also interact
with joinder section 92 and may be the sole section on linkage 2F
to couple with block 90. In accordance with this embodiment, the
smaller diameter D.sub.m may be used to weld linkage 2F to block 90
while the larger diameter D may exist outside of the junction zone
formed by joinder 92 and surface .GAMMA.. An exemplary surface
.GAMMA. may be equal to approximately 0.465*D or approximately
1.500*T.sub.C.
[0149] In the exemplary embodiment of FIG. 19D, an exemplary
integrated Lego-like block 80/90 may also have a user force applied
to its integrated linkage 2E or weld linkage 2F so as to cause
either linkage to maintain a pose .rho. in the x-, y-, and z-plane.
The origin of the pose .rho. may be found at the junction of the
axis of an exemplary linkage 2E/2F and the orthogonal surface of
Lego-like block 80/90. If Lego-like block 80/90 does not have an
orthogonal surface, then the plane tangent to the first surface
which contacts linkage 2E/2F may be suitable as a plane for the
origin point, although persons skilled in the art may choose other
suitable origin points. The .rho. of an exemplary integrated
linkage 2E or weld linkage 2F may the same or similar to that of an
exemplary linkage 2 with the exception that block 80/90 necessarily
will be involved in the pose. In other words, blocks 80/90, like an
elaborate face coating 2C/2D are one with the linkage 2E/2F. In an
exemplary embodiment, I.sub.M<I.sub.C for integrated linkage 2E
or weld linkage 2F. According to this exemplary embodiment, the
ratio of I.sub.C/I.sub.M for an exemplary posable integrated
linkage 2E or posable weld linkage 2F may be greater than about 1
but less than about 55.
[0150] While exemplary linkages 2 may be illustrated in
cross-section and in full by FIGS. 16A-D, FIGS. 18A-D, and FIGS.
19A-D, those skilled in the art will readily understand these
illustrations may apply to sections, subsections, ends, or
combinations of the same for an exemplary linkage 2 in whole or in
part from various vantage points and in any of the other
embodiments and interrelated embodiments as disclosed and/or
described.
[0151] Many further variations and modifications may suggest
themselves to those skilled in art upon making reference to above
disclosure and foregoing interrelated and interchangeable
illustrative embodiments, which are given by way of example only,
and are not intended to limit the scope and spirit of the
interrelated embodiments of the invention described herein. While
many of the exemplary bricks 10/30-90 have been disclosed, these
exemplary bricks may be integrated components with other exemplary
building blocks and need not exist in isolation. Thus, it is
contemplated that the exemplary bricks 10/30-90 and their various
surface structures and dimensions may be utilized in conjunction
with and as integrated parts of presently available building block
systems in addition to functioning on their own.
* * * * *
References