CN105007997A - Constructional toy - Google Patents

Abstract

A constructional toy comprising a first element (10) and a second element (12). The first element (10) has a first engagement surface (14) and a first engagement feature (16) located adjacent the first engagement surface (14). The second element (12) has a second engagement surface (24) and a second engagement feature (26) located adjacent the first engagement surface (24). The engagement feature (16,26) are configured such that the act of urging the engagement feature (16,26) of one element (10,12) into engagement with the engagement feature (16,26) of the other element (10,12) biases the engagement surfaces (14,24) into frictional engagement with one another.

Description

building toys

technical field

The present disclosure relates to a construction toy.

In particular, the present disclosure relates to a construction toy comprising a first element and a second element.

Background technique

Construction toys having separate construction elements are well known in the art. For example UK patent application GB2224953 describes a construction toy comprising a plurality of primary construction elements having wedge shaped grooves and wedge shaped connecting members. These primary construction elements can be combined to build shapes for the entertainment and education of children. WO97/01383 describes an alternative construction toy of the same kind but with splines provided as engaging features.

Such toys are usually made of injection molded plastic. Varying material properties that cause shrinkage and deformation make it difficult to manufacture combinations of elements that fit together well to retain their shape and that are simple enough for children to assemble and construct. For example, if the gap between the splines of the female engaging features is too large and the splines of the male engaging features are too small, the bond between the two features will be loose, which can cause the parts of the toy to come apart too easily. Alternatively, if either of the splines of the female engaging feature is oversized and the corresponding splines of the male engaging feature are oversized, then the bond between the splines of the parts will be very tight and will not be safe for children. may be difficult to fit together and/or take apart.

Furthermore, since satisfactory assembly and disassembly of the toy elements is dependent on frictional contact between all the splines, any unevenness in the surface of the splines can make the assembly and disassembly of the elements difficult. For this reason, irregularities introduced by injection molding injection points for delivering plastic are not conventionally located on or adjacent to the splines, but usually on the outside of the brick, which can be unsightly.

Consistently manufacturing parts with tight tolerances is difficult with plastic materials and conventional manufacturing methods. Furthermore, the dimensions of different dies and cutting tools for the same or similar parts vary due to manufacturing variations of the dies and tools. Thus, a part made with a first combination of mold and tool may have different dimensions than the same part made with a second combination of mold and tool that has dimensions of Nominally the same design dimensions as the first combination. Furthermore, the dimensions of molds and tools will change with constant use as the parts wear and will change due to thermal and mechanical cycling. These combined changes lead to serious binding problems. Also, in the event that a mold or tool becomes unacceptable, it may have to be scrapped altogether.

As a result, a significant percentage of parts in the manufacturing process have joined features that are either too large or too small. Consequently, either non-conforming parts may be delivered to the customer and/or the manufacturer must conduct thorough inspections for the quality of the parts, discarding and disposal of completed components that do not meet the required standards, thereby increasing time and cost for manufacturing. Quality assurance checks are further complicated by the fact that the dimensions of the plastic change within a few hours after the manufacturing steps have been completed, so a part that meets quality standards just after manufacturing may not be up to standard after a few hours.

Accordingly, it would be highly desirable to design a construction toy that avoids these processing and manufacturing issues, thereby making processing and manufacturing simpler and thus providing a toy with reliable and consistent assembly and disassembly resistance and improved aesthetic appearance The product.

Contents of the invention

According to the present invention there is provided a construction toy and method of manufacture as set forth in the appended claims. Other characteristics of the invention will be apparent from the dependent claims and the following description. There may be provided a construction toy comprising: a first element and a second element; the first element having a first engagement surface and a first engagement feature; the second element having a second engagement surface and a second engagement feature; the engagement feature It is configured such that the act of forcing the engagement feature of one element into engagement with the engagement feature of the other element biases the engagement surfaces into frictional engagement with each other.

The first engagement feature may include a wall portion defining a recess extending below the first element engagement surface and a first spline extending from the recess wall over a portion of the recess but not beyond Throughout the recess, the first spline has an inner surface and an outer surface, the inner surface facing inwardly of the recess, the outer surface facing outwardly of the recess; and the second engagement feature comprises a second spline on the second element engaging surface Extending above, the second spline has an inner surface facing the second element engaging surface and an outer surface facing away from the second element engaging surface; such that the second spline enters the recess and forces the inner surface of the spline The engagement surfaces of the first and second elements are biased into frictional engagement with each other when the surfaces are engaged with each other.

The first element engaging splines and the second element engaging splines may be configured to contact each other at points along their respective inner surfaces.

Prior to assembly, the contact point on the first element engaging spline may be at a first distance (x) from the first element engaging surface and the contact point on the second element engaging spline at a second distance from the second element engaging surface (y), the second distance (y) is less than the first distance (x).

At least one of the engagement features may be elongate and extend along a generally straight line.

The first element may include a third spline that is substantially identical to the first spline, the third spline extending from the wall of the recess towards the first spline across a portion of the recess but not across the entire recess; the second element may include the same The second spline is substantially the same as a fourth spline extending from the second element engaging surface in a direction away from the second spline; such that the fourth spline enters the recess and forces the inner surfaces of the splines to each other When engaged, the first element engaging surface and the second element engaging surface are brought into frictional engagement with each other.

The first engagement feature may comprise additional splines extending from the wall of the recess.

The second engagement feature may include additional splines extending from the second element engagement surface.

The first engagement feature may include additional splines extending from the wall of the recess; the second engagement feature may include additional splines extending from the second element engagement surface; and the first element engagement feature spline spacing may be greater than the first element engagement feature. The width of the two-element engaging feature splines is large such that when the second element engaging splines enter the recess, the inner surfaces of some of the first element engaging splines are forced to engage some of the second element engaging splines. The inner surface of the key engages, the engaged second element engaging feature splines each substantially in contact with only one of the first element engaging feature splines, the remaining second element engaging feature splines engaging the remaining first element The feature splines are spaced apart.

The construction toy may be configured such that when the second element engages the feature splines enters the recess and forces the first element to engage the inner surface of some of the splines and the second element to engage the inner surface of some of the splines When engaged, up to four of the second element engagement feature splines are each substantially in contact with only one of the first element engagement feature splines, the remaining second element engagement feature splines are in contact with the remaining first element engagement feature splines. The element engaging features are splined apart.

The construction toy may be configured such that when the second element engages the feature splines enters the recess and forces the first element to engage the inner surface of some of the splines and the second element to engage the inner surface of some of the splines When engaged, up to two of the second element engagement feature splines are each substantially in contact with only one of the first element engagement feature splines, the remaining second element engagement feature splines are in contact with the remaining first element engagement feature splines. The element engaging features are splined apart.

The first element engagement feature spline may be shorter than the second element engagement feature spline.

The first element engaging feature spline closest to the first element engaging surface may be shorter than the first element engaging feature spline furthest from the first element engaging surface.

The second element engaging feature splines closest to the second element engaging surface may be longer and/or wider than the second element engaging feature splines furthest from the second element engaging surface.

The elements for building the toy may have an outer wall, and the engagement surface is provided on the outer wall.

The first element engaging surface may be disposed on a first engaging feature spline extending from the first element; the second element engaging surface may be disposed on a second element engaging spline extending from the second element; the first element engaging feature disposed on in the region between the additional first element engagement feature splines; and the second element engagement feature is an end of a push spline extending from the second element to push against the first element engagement feature.

The second element pushing splines may be longer splines than the splines defining the second element engagement surface.

The first element engagement spline comprising the first element engagement surface may be longer and/or wider than the additional first element engagement feature spline.

The first element spline spacing may be greater than the width of the second element splines.

The first engaging feature spline comprising the first element engaging surface is wider than the other first element engaging splines in the region of the first element engaging surface such that the first element engaging spline is forced between the second element engaging spline The action of the splines biases the engaging surfaces of the splines into frictional engagement with each other.

The protrusion may extend above the second element engagement surface, and the one or more second element engagement feature splines extend from the protrusion.

The recesses and protrusions may be complementary in shape.

The recess may be concave in cross-section, and the protrusion may be convex in cross-section.

The recesses and protrusions may be arcuate in cross-section.

The construction toy may also include a third element for engaging the first element, the third element including a mandrel and a plurality of splines extending from the shaft for engagement with at least one of the first elements. A bonded feature is bonded.

There may also be provided a method of manufacturing a construction toy of the present disclosure, the method comprising the steps of: constructing an injection mold for the elements of the toy; Key features such that in the finished element the injection point is adjacent to the base of the spline or substantially at the top of the spline.

The apparatus and method of manufacture of the present disclosure are further described in the following paragraphs.

There may also be provided a construction toy comprising: a first element and a second element; each of the elements having at least one engagement surface and at least one engagement feature located adjacent the at least one engagement surface. The engagement features are configured such that the act of forcing the engagement feature of one element into engagement with the engagement feature of the other element frictionally engages the engagement surfaces with each other. Thus, a construction toy is provided in which the behavior of the elements is less sensitive to manufacturing tolerances than in the prior art. To achieve this improved performance, the construction toy has two modes of engagement. The engagement feature attaches the first and second elements together and draws the sides of the first and second elements together such that a joint is formed between contact/engagement surfaces of the first and second elements adjacent the engagement feature. interference fit.

The first engagement feature may include a wall portion defining a recess extending below the first element engagement surface and a first spline; the first spline extending from the wall portion of the recess across a portion of the recess but not across the entire a recess; the first spline has an inner surface and an outer surface, the inner surface faces inwardly of the recess, the outer surface faces outwardly of the recess; and the second engagement feature comprises a protrusion and a second spline, the protrusion on the second element engaging surface Extending above; the second spline extends from the protrusion; the second spline has an inner surface and an outer surface, the inner surface faces the second element engaging surface, and the outer surface faces away from the second element engaging surface; such that at the protrusion Entering the recess and forcing the inner surfaces of the splines into engagement with each other brings the engaging surfaces of the first and second elements into frictional engagement with each other. Thus, the splines of the engagement features act to draw the engagement surfaces of the elements together such that an interference fit is formed between the contacting/engagement surfaces of the elements adjacent the engagement features.

The first spline and the second spline may be configured to contact each other at points along their respective inner surfaces. Prior to assembly, the contact point on the first spline is at a first distance from the first engagement surface, and the contact point on the second spline is at a second distance from the second contact surface, the second distance being less than the first distance .

The recesses and protrusions may be complementary in shape. The recess may be concave in cross-section, and the protrusion may be convex in cross-section. The recesses and protrusions may be arcuate (ie curved, with a constant or varying radius) in cross-section. At least one of the engagement features may be elongate and extend along a generally straight line.

The first element may include a third spline that is substantially identical to the first spline, the third spline extending from the wall of the recess towards the first spline across a portion of the recess but not across the entire recess; the second element may include the same The second spline is substantially the same as the fourth spline, which extends from the protrusion in a direction away from the second spline; such that when the protrusion enters the recess and forces the inner surfaces of the splines to engage each other, the first The engagement surfaces of the element and the second element are in a friction/interference engagement relationship with each other.

The first engagement feature may comprise additional splines extending from the wall of the recess. The second engagement feature may include additional splines extending from the protrusion.

The first engagement feature may include additional splines extending from the wall of the recess; the second engagement feature may include additional splines extending from the protrusion; and the first element splines may be spaced a distance wider than the width of the second element splines so large that when the protrusion enters the recess and forces the inner surfaces of the splines into engagement with each other, at least some of the splines of the second element are each substantially in contact with only one of the splines of the first element, and the rest The second element splines are spaced apart from the remaining first element splines. This provides the advantage that the engaging surfaces of the elements are pulled together by the splines that are in contact. It also allows splines that are not in contact with another spline but may be required to position the elements together to move freely past each other without increasing the amount of force required to assemble the elements of the toy.

The first element splines may be shorter than the second element splines. The splines of the first element closest to the engagement surface of the first element may be shorter than the splines of the first element furthest from the engagement surface of the second element. The splines of the second element closest to the second element engagement surface may be longer and/or wider than the second element splines furthest from the second element engagement surface.

The construction toy may also include a third element for engaging the first element, the third element including a mandrel and a plurality of splines extending from the shaft for engagement with at least one of the first elements. A bonded feature is bonded. This provides manufacturing advantages that are only possible due to the configuration of the engagement features of the present disclosure.

There may also be provided a method of manufacturing a construction toy as described above, the method comprising the steps of: constructing an injection mold for the elements of the toy; constructing the mold such that the injection point for the fabrication material is adjacent to an injection mold of the mold The features of the spline are defined so that in the finished component, the injection point is adjacent to the base or top of the spline. This offers the advantage that the injection molding point is partially hidden from the user. This results in a smoother finish, which is both aesthetically and ergonomically more pleasing to the user than would be the case if the injection point were on the outer surface as in prior art manufacturing methods.

Description of drawings

Examples of the present disclosure will now be described with reference to the accompanying drawings, in which:

Figures 1 to 6 illustrate a construction toy with interlocking features;

Figure 7 illustrates a construction toy of the present disclosure having engagement features that join together the elements of the construction toy;

Figure 8 illustrates an alternative example of a construction toy of the present disclosure having engaging features;

Figure 9 shows various examples of geometries to which the features of the present disclosure may be applied;

Figure 10 shows a first element having a recessed engagement feature according to the present disclosure;

Figure 11 shows a second element having a male engagement feature for engagement with the engagement feature of Figure 10;

Figure 12 shows the engagement features of the first and second elements shown respectively in Figures 10 and 11 when forced into engagement with each other;

Figure 13 shows an enlarged view of the interlocking engagement features as shown in Figure 12;

Figure 14 shows a cross-sectional view of an alternative example engagement feature to that shown in Figure 13, with certain details removed for clarity;

Figure 15 shows elements of a construction toy joined together by alternative engagement features;

Figure 16 shows an enlarged view of the engagement features of the construction toy elements of Figure 15;

Figure 17 shows elements of a construction toy similar to that of Figure 15, but with a different shape;

Figures 18 and 19 show perspective views of the construction toy shown in Figure 17;

Figure 20 shows an example of two differently shaped elements of a construction toy joined together using the engagement features of the present disclosure;

Figure 21 shows an alternative male engagement feature;

Figure 22 shows another alternative element for building a toy;

Figure 23 shows an example of differently shaped elements of a construction toy joined together by engagement features according to the present disclosure; and

24 and 25 illustrate examples of injection molding locations according to the present disclosure.

Detailed ways

Figures 1 to 6 are provided as a background for understanding the construction toy of the present disclosure and, as manufactured, will have the disadvantages of the related art. FIG. 1 shows elements 200 , 202 of a construction toy joined by interlocking features shown generally at 204 . Elements 200, 202 are toy bricks having features on each side for interlocking engagement with features of the other elements. The element has a square cross-section. Similar elements 206 , 208 are shown in FIG. 2 . An enlarged view of the interlock feature 204 is shown in FIGS. 3 and 4 . Interlock Features 204

Included are a plurality of splines 210 disposed on a side 212 of one element and a plurality of splines 214 disposed on a side 216 of the other element. As shown in FIG. 4, when the splines 210, 214 slide together so that they form an interlock, each of the splines frictionally engages the other, and some of the splines The splines are in frictional engagement with two other splines. The splines 210, 214 hold the elements together such that the sides/faces 212, 216 of the elements remain in loose contact and are free to move relative to each other.

Also, in the example of FIGS. 5 and 6 , element 220 and element 224 are coupled together by interlock 204 , and interlock 204 includes splines 226 on one element and splines on the other element 224 228. The means for interlocking are the same as in the previous figures. When the splines 226 enter the gaps disposed between the splines 228 , the splines 226 are substantially restrained and the elements 220 , 224 are held together due to the frictional contact between the splines 226 , 228 . Although the sides/faces 212, 216 of the elements may touch, they only touch loosely/lightly.

That is, the splines of the example of FIGS. 1-6 are dimensioned such that when all the splines of the two elements are engaged, frictional contact between the splines holds the blocks together. There is no frictional engagement between the faces/sides of the blocks.

Examples of construction toys of the present disclosure described herein are configured so that the splines of the different toy elements will fit and interact differently, that is, with different contact and bonding relationship and methods.

7 and 8 illustrate examples of construction toys comprising a first element 10 and a second element 12 according to the present disclosure. Similar features are described using common reference numerals. The first and second elements are shown as cross-sections of generally polygonal components. However, the present disclosure is not limited to these shapes. Shown in FIG. 9 are a number of examples of different shapes in which the engagement surfaces and engagement features described herein may be employed. For example, elements according to the present disclosure may be generally square and have the shape of the examples "J", "K", "L". Alternatively, the elements may be triangular in shape and include complementary elements, such as an example "M" and an example "Q". FIG. 9 shows further examples of building elements of the present disclosure, which will be mentioned and described later. Furthermore, one or more of the shaped elements may be circular, as shown in FIGS. 20 , 23 , 24 , 25 .

Figure 10 shows a first element 10 of the building toy. Figure 11 shows a second element 12 of the same construction toy. The elements can be assembled together to form a wide variety of three-dimensional structures. The first element 10 has an engagement surface 14 and an engagement feature 16 located adjacent the engagement surface 14 . Although not shown in detail, the first element 10 also has further engagement surfaces 14 and further engagement features 16 on different sides of the first element 10 .

The second element 12 has an engagement surface 24 and an engagement feature 26 located adjacent the engagement surface 24 . As with the first element, the second element 12 also has at least one further engagement surface 24 and further engagement features 16 .

In both cases, the engagement features 16 , 26 are flanked by the engagement surfaces 14 , 24 . That is, the engagement surfaces 14 , 24 exist on either side of the engagement features 16 , 26 . In other words, there may be at least two engagement surfaces 14 , 24 associated with each engagement feature 16 , 26 on each side of an element 10 , 12 . The engagement surfaces 14, 24 may be generally planar (ie, planar).

The first engagement feature 16 includes a wall portion 28 defining a recess 30 extending below the level of the first element engagement surface 14 . That is, the first engagement feature 16 comprises a groove formed in a wall portion defining the periphery of the first element 10 . In other words, the first engagement feature 16 comprises a groove provided in a wall portion of the first element 10 below the plane of the engagement surface 14 . The first engagement feature 16 also includes a first spline 32 that extends from the wall of the recess 30 across a portion of the recess 30 but not across the entirety of the recess 30 . The first spline 32 has an inner surface 34 facing inwardly of the recess 30 and an outer surface 36 facing outwardly of the recess 30 .

The second engagement feature 26 includes a protrusion 40 that extends above (ie, away from) the second component engagement surface 24 . A second spline 42 extends from the protrusion 40 . The second spline 42 has an inner surface 44 facing the second element engaging surface 24 and an outer surface 46 facing away from the second element engaging surface 24 .

As shown in FIGS. 10 and 11 , the recess 30 and the protrusion 40 are complementary in shape. In the example shown, the recess 30 is concave in cross-section and the protrusion 40 is convex in cross-section. Furthermore, the recess 30 is shown as being arcuate in cross-section, and the protrusion 40 is shown as being arcuate in cross-section. However, these are only examples, and the recesses and protrusions may have different shapes, for example, they may be polygonal in nature. At least one of the engagement features 16, 26 is elongated and extends in a generally rectilinear manner. That is, as shown in FIGS. 10 and 11 , the recesses and/or protrusions 26 may extend into the page and/or out of the page.

As shown in FIGS. 10 and 11 , the first member 10 and the second member 12 may include a plurality of additional splines. That is, each of the first element 10 and the second element 12 may include at least two splines. For example, the first element 10 comprises a third spline 50 substantially identical to the first spline 32, wherein the third spline 50 extends from the wall of the recess 30 over a part of the recess 30 towards the first spline 32, and It does not extend across the entire recess 30 . The second element 12 also includes a fourth spline 52 substantially identical to the second spline 42 , wherein the fourth spline 52 extends from the protrusion 40 in a direction away from the second spline 42 .

The first engagement feature 10 includes additional splines 54 , 56 , 58 , 60 , 62 that extend from the recess between the first spline 36 and the third spline 50 . The wall portion of 30 extends. The second engagement feature 26 includes additional splines 64 , 66 , 68 , 70 extending from the protrusion 40 between the second spline 42 and the fourth spline 52 .

The locations of the splines on the recess wall 28 and protrusion 40 are shown by way of example only. For example, although the first spline 36 and the third spline 50 are shown flush with the engagement surface 14, they may actually be positioned spaced apart from the engagement surface, for example in a position similar to that of the splines 54, 62. middle.

It is essential that the first element 10 and the second element 12 each comprise at least one spline. Preferably, and as noted above, the first member 10 and the second member 12 include a second spline generally opposite the first spline on their respective engagement features. That is, it is preferred that the first element 10 has a first spline 32 on one side of the recess 30 and an additional spline 50 on the other side of the recess 30 . Accordingly, it is preferred that the second element comprises a first spline 42 on one side of the protrusion 40 and an additional spline 52 generally opposite the first spline 42 on the other side of the protrusion 40 .

As shown in Figure 12, the first element 10 and the second element 12 are shown engaged with each other via their engagement features 16, 26, respectively. An enlarged view of the engagement features 16 , 26 is shown in FIG. 13 .

At least two splines - one from element 10 or element 12 - are configured to contact each other at points along their respective inner surfaces. For example, as shown most clearly in FIG. 13 , the splines 62 of the first element 10 are configured to contact the splines 70 of the second element, and the splines 54 of the first element 10 are configured to contact the splines of the second element 12. key64. Additionally, the first splines 32 and the second splines 42 may be configured to contact each other at points along their respective inner surfaces.

The point of contact on the splines of the first element is indicated by reference numeral 38 . The point of contact on the splines of the second element is indicated by reference numeral 48 . The term "point of contact" is intended to mean an area or area. Prior to assembly, the contact point 38 on the first element spline 62 is a first distance "x ₁ " from the first engagement surface 14 and the contact point 48 on the second element spline 70 is a second distance "x1" from the second contact surface 24. y ₁ ". Additionally and optionally, prior to assembly, the contact point 38 on the first element spline 32 may be a first distance "x ₂ " from the first engagement surface 14 and the contact point 48 on the second element spline 42 a distance "x2" from the first engagement surface 14. The second distance "y ₂ " from the two contact surfaces 24 .

The second distance "y ₁ , y ₂ " is smaller than the first distance "x ₁ , x ₂ ".

In the example shown, the element is configured such that when the protrusion 40 enters the recess 30, the third spline 50 and the fourth spline 52 also have a contact point, the position of the contact point on each spline is selected such that The engagement surfaces of their respective elements are in frictional contact. Likewise, splines 54 and 64 and splines 62 and 70 may also have contact points, the locations of the contact points on each spline being selected such that the engaging surfaces of their respective elements are in frictional contact. That is, at least two of the second element splines 42 , 52 , 64 , 70 are each substantially in contact with one of the first element splines 32 , 50 , 54 , 62 respectively. The splines are also configured such that the remaining second element splines 66, 68 are spaced apart from the first element splines 56, 58, 60, respectively. In other words, at least some, but not all, of the second element splines are each substantially in contact with a corresponding first element spline, and the remaining splines of the second element splines are in contact with their respective first element splines. Essentially spaces (or voids) are provided between the element splines. Furthermore, splines that are in contact with each other will only contact each other at contact points/regions 38, 48, where a space (or void, or gap) is substantially provided between the respective outer surfaces of the splines. That is, a spline that is in contact with another spline is only in contact with one other spline, and thus is in contact with the other spline at only one of the two sides of the spline (not both sides).

Thus, and as shown in Figure 13, only some of the splines may be forced to engage each other. The example in FIG. 13 is configured such that up to four of the second element splines (i.e., splines 42, 52, 64, 70) are each substantially separate from the first element splines (i.e., splines 32, 50, 70). 54, 62) only one of the splines is in contact, the remaining second element splines are spaced from the remaining first element splines.

In an alternative example, the splines and elements are configured such that at most two of the second element splines are each substantially in contact with only one of the first element splines, the remaining second element splines are in contact with The remaining first element splines are spaced as shown in FIG. 14 .

Figure 14 shows a view similar to that shown in Figure 13, except that in this example it can be observed that the splines 42, 52 of the second element 12 are in contact with the splines 32, 50 of the first element 10 and None of the other splines touch each other. However, the interaction of the contacting splines biases the engagement surfaces 14, 24 into frictional engagement with each other. A spline that is in contact with another spline is only in contact with one other spline, and thus only one side of each of the contacting splines is in contact with the other spline.

The first element splines 32 , 54 , 56 , 58 , 60 , 62 are shorter than the second element splines 42 , 52 , 64 , 66 , 68 , 70 . That is, the distance from the wall of the recess 30 to the highest point/distal point on the spline of the first element 10 is less than the distance from the wall of the protrusion 40 to the highest point/distal point on the spline of the second element 12 The distance from the endpoint. The splines of the second element closest to the second element engagement surface are longer and/or wider than the splines furthest from the second element engagement surface.

The engagement features 16, 26 are configured such that when forced into engagement with each other, the engagement surfaces 14, 24 are forced into a friction/interference engagement relationship with each other. That is, when the protrusion 26 enters the recess 30 and forces the inner surfaces 34, 44 of the splines (see FIGS. 10, 11 ) into engagement with each other, the engagement surface 14 of the first element 10 and the second element 12 engage. The surfaces 24 are in a frictional interference engagement relationship with each other.

In other words, the contact points of each element contacting the splines are spaced a distance from the engagement surfaces of the corresponding element contacting the splines such that when the splines engage each other, the engagement surfaces of the elements are forced together.

As shown in Figure 13 or Figure 14, any error or variation in shape of the intermediate splines, ie, splines 56, 58, 60 and 66, 68, does not affect the engagement performance of the engagement features. Thus, a pull fit type arrangement is provided in which the engagement surfaces 14, 24 of the elements are pulled together by the action of the splines of the engagement features.

Figures 15 to 19 show alternative arrangements for coupling construction toy elements 10, 12 to each other. As can be seen in FIG. 15 , each element includes a male spline extending away from the engagement surface 14 , 24 of the element 10 , 12 and also includes a female spline in a recess 30 for receiving the male spline. splines.

Figure 16 shows an enlarged view of the junction area. The recess 30 is provided in the engagement surface 14 of the first element 10 and includes first element engagement splines 32a, 50a (similar to the splines 32, 50 shown in Figures 10-14). Another spline 58a is provided extending outwardly from the wall of the recess. The second element 12 is provided with splines 42a, 52a extending from the engagement surface 24 of the second element 12 . The splines are similar to the second element engaging splines 42, 52 shown in FIGS. 10-14. The engagement splines are sized and spaced such that the act of forcing the second element engagement splines 42a, 52a into engagement with the first element engagement splines 32a, 50a, 58a biases the engagement surfaces 14, 24 against each other. That is, the splines of the example shown in FIG. 16 are sized, positioned and configured such that when they are pushed together, the surfaces 14, 24 of the elements 10, 12 are drawn together and effectively force the surfaces 14, 24 frictionally engage each other.

Figure 17 shows an alternative shaping element (triangular) to that shown in Figures 15, 16 . 18 and 19 show perspective views of the elements shown in FIG. 17 .

Fig. 20 shows another example of a construction toy according to the present disclosure. A first element 10 (shown in this example as a circular element) is joined to a second element 12 (shown in this example as a polygonal shaped element). Since the first element 10 is circular, its outer surface 14A will not be in contact with the outer surface 24 of the second element 12 . Thus, in this example, a first element engaging surface 71 is provided on the first engaging feature splines 54 , 62 extending from the first element 10 . A second element engaging surface 73 is provided on the second element engaging splines 64 , 70 extending from the second element 12 . In the region between the additional first element engaging feature splines 56A, 58A, 60A there is provided a first element engaging feature 75 . The second element engagement feature 77 is provided as the end of a push spline 66A, 68A extending from the second element 12 to push against the first element engagement feature 75 .

The second element pushing splines 66A, 68A are longer than the splines 64 , 70 defining the second element engaging surface 73 and may be narrower than the splines 64 , 70 defining the second element engaging surface 73 .

The first element engagement splines 54, 62 including the first element engagement surface 71 are longer than the additional first element engagement feature splines 56A, 58A, 60A and may be longer than the additional first element engagement feature splines 56A, 58A, 60A wide.

The first element splines 54 , 56A, 58A, 60A, 62 are spaced apart by a greater distance than the width of the second element splines 52 , 64 , 66A, 68A, 70 , 42 .

The distance between the first element engaging splines 54, 62 comprising the first element engaging surface 71 may be greater than the distance between the second element engaging splines 52, 64, 66A, 68A, 70, 42 in the region of the first element engaging surface 71 Width.

The first element engaging splines 54, 62 comprising the first element engaging surface 71 may be in the region of the first element engaging surface 71 more than other first element engaging splines (56A, 58A, 56A, 58A, 60A) wide.

Thus, with this configuration, the act of forcing the first element engaging splines 54, 56A, 58A, 60A, 62 between the second element engaging splines 52, 64, 66A, 68A, 70, 42 causes the splines 54, Engagement surfaces 71 of 62 and engagement surfaces 73 of splines 64, 70 are biased into frictional engagement with each other.

In the example of FIG. 20, the longer splines 66A, 68A of the second element bias the splines 64, 70 of the second element 12 into contact with the first element splines without themselves being in frictional contact with the first element splines. The splines 54, 62 of the element 10 are in frictional engagement. Thus, the first element engagement splines 54, 62 and the second element engagement splines 64, 70 provide engagement surfaces that push against the engagement features 66A, 68A (push splines 66A, 68A) of the first element. The engagement features of the second element (recesses between the splines 56A, 58A, 60A of the first element) are then biased into frictional engagement with each other.

Figure 21 shows an alternative shaped element 70 which differs from the first element 10 in that the engaging surface 24 is truncated compared to the engaging surface 24 of the example of Figure 11, the design of the splines and The mode of operation is the same as previously described.

FIG. 22 shows a third element 80 for engagement with the first element 10 and other such elements having female engagement features/recesses 30 . A side view of a different example of element 80 is shown in FIG. 9 (see examples "A", "B", "C", "D", "E"). The third element 80 includes a mandrel 82 and a plurality of splines 84 extending from the shaft 82 for engagement with the engagement features of the first element 10 . The third element shown in FIG. 22 is substantially cylindrical in nature and extends inwardly of the page as well as outwardly of the page as shown in FIG. 22 . This third element 80 has an outer diameter defined by the radially outermost point of the spline 84 . The tool for machining the shaft is configured to perform an injection molding operation to produce the shaft shape.

The example shown in FIG. 23 shows a first element 10 and a second element 12A of a construction toy of the present disclosure joined by a third element 80 as discussed with reference to FIG. 22 . All splines 80 are substantially identical in design. However, the splines of the first element 10 and the second element 12A are dimensioned as described with reference to FIG. 20 and elements 10 , 12 . That is, the engaging splines 54, 62 of each element 10, 12 are longer than the additional splines 56A, 58A, 60A, and may each be wider than the additional splines 56A, 58A, 60A.

The construction toys described herein can be manufactured by injection molding as previously discussed. In injection molding, a mold is constructed that defines the shape of the part to be formed. Injection molding holes are provided in the mold. In the method of making a construction toy described herein, the mold is configured such that the injection point of the material used to make it is adjacent to a feature of the mold that defines the spline, so that in the finished element, the injection point 90 is adjacent to the spline such as spline 58. base, as shown in Figure 24. As used herein, "base" refers to the surface/substrate from which spline extension begins. Thus, for example, the injection point may be located between two of the splines, such as between the splines 58 , 60 and/or the splines 66 , 68 .

Alternatively, the mold may be configured such that the injection point of the material used for manufacture is adjacent to a feature of the mold that defines the spline, so that in the finished element, the injection point 90 is toward or at the top of the spline, as in shown in Figure 25. Herein, "top" refers to the end of the spline remote from the base of the spline.

As described above with respect to at least the examples of Figures 13, 14, the injection molding can be positioned at this point only due to the central spline (66, 68 and 58, 60 shown in the example) configuration and are dimensioned such that there is space (ie void or gap) between said central splines when the toy elements are assembled. Thus, any unevenness in the surface of the material due to the injection point is adjusted. That is, in instances where the surfaces of the splines 58, 60, 66, 68 are not in frictional engagement with each other in operation, the location of injection molding marks on the surfaces of these splines, particularly at their bases or tops will not interfere with the operation of the component.

Thus, there is provided a construction toy consisting of a plurality of elements which can be easily assembled by a user, eg a child, but which are also configured to be held together. That is, the plastic elements that build the toy touch in a position that is frictionally engaged enough so that the elements do not slip or fall apart, but not so firmly engaged that the elements snap together so that a child cannot easily move them separately. As noted above, in operation some but not all of the splines contact the respective splines. Thus, with a small number of such contact surfaces (compared to the prior art), errors in manufacturing have less impact on the overall operability. Furthermore, since fewer splines are required for the engagement of the elements, the load per spline is increased, so each spline may be tilted so as to bend/bend, further accommodating manufacturing tolerances Variety.

Referring to the relative dimensions of the features of the present disclosure, such as the width and length of the splines, the corresponding drawings may exaggerate differences in dimensions, which are actually minor. However, it should be noted that although the differences are small, they have large practical significance. Features of the disclosure cannot be measured or inferred from the drawings.

While the preferred embodiment(s) of the invention have been shown and described, those skilled in the art will appreciate that, without departing from the scope of the invention as defined in the claims, Various modifications can be made.

Claims (28)

1. A construction toy comprising: a first element (10) and a second element (12); The first element (10) has a first engagement surface (14) and a first engagement feature (16); The second element (12) has a second engagement surface (24) and a second engagement feature (26); The engagement features (16, 26) are configured such that: the engagement features (16, 26) of one element (10, 12) are forced with the engagement features (16, 26) of the other element (10, 12) The act of engaging biases the engaging surfaces (14, 24) into frictional engagement with each other. 2. The construction toy of claim 1, wherein: The first engagement feature (16) includes: a wall portion (28) defining a recess (30) extending below the first element engaging surface (14); and a first spline (32) extending from a wall of said recess (30) across a portion of said recess (30) but not across the entirety of said recess (30); The first spline (32) has an inner surface (34) and an outer surface (36), the inner surface (34) faces into the recess (30), and the outer surface (36) faces the recess ( 30) outside; and The second engagement feature (26) includes: a second spline (42) extending above the second element engaging surface (24); The second spline (42) has an inner surface (44) facing towards the second element engaging surface (24) and an outer surface (46) facing away from the second element engaging surface (46). engaging a surface (24) to said second element; such that when said second splines (42) are brought into said recesses (30) and said inner surfaces (34, 44) of said splines (32, 42) are forced into engagement with each other, said first element (10) and said engagement surfaces (14, 24) of said second element (12) are biased into frictional engagement with each other. 3. A construction toy according to claim 2, wherein said first element engaging splines (32) and said second element engaging splines (42) are configured to move along their respective inner surfaces (34, 44) are in contact with each other at points (38, 48). 4. A construction toy according to claim 3, wherein, prior to assembly, said point of contact on said first element engaging spline (32) is a first distance from said first element engaging surface (14) (x), and said point of contact on said second element engagement spline (42) is a second distance (y) from said second element engagement surface (24), said second distance (y) being less than The first distance (x). 5. A construction toy according to any one of the preceding claims, wherein at least one of the engagement features (16, 26) is elongate and extends along a substantially straight line. 6. A construction toy according to any one of claims 2 to 5, wherein: Said first element (10) comprises a third spline (50) substantially identical to said first spline (32), said third spline (50) extending from said recess wall towards said first a spline (32) extending across a portion of said recess (30) but not across the entirety of said recess (30); The second element (12) includes a fourth spline (52) substantially identical to the second spline (42), the fourth spline (52) extending from the second element engagement surface (24) extending in a direction away from said second spline (42); such that when said fourth spline (52) is brought into said recess (30) and said inner surfaces of said splines are forced into engagement with each other, said first element engaging surface (14) and said second The two element engaging surfaces (24) frictionally engage each other. 7. A construction toy according to any one of claims 2 to 7, wherein the first engagement feature (16) comprises an additional spline extending from the wall portion of the recess (30). 8. A construction toy according to claims 2 to 6, wherein the second engagement feature (26) comprises an additional spline extending from the second element engagement surface (24). 9. A construction toy according to any one of claims 2 to 6, wherein: said first engagement feature (16) includes additional splines extending from said wall portion of said recess (30); The second engagement feature (16) includes additional splines extending from the second element engagement surface (24); and The first element engagement feature splines are spaced at a distance greater than the width of the second element engagement feature splines such that when the second element engagement splines are brought into the recess (30), the When the inner surfaces of some of the first element engaging splines are engaged with the inner surfaces of some of the second element engaging splines, the engaged second element engaging feature splines are each Substantially in contact with only one of said first element engaging feature splines, the remainder of said second element engaging feature splines being spaced apart from the remainder of said first element engaging feature splines. 10. A construction toy according to claim 9, configured such that when said second element engaging feature splines are brought into said recess (30) and some of said first element engaging splines are forced When the inner surface of said second element engaging feature splines is engaged with said inner surface of some of said second element engaging feature splines, each of up to four of said second element engaging feature splines is substantially Only one of the splines of an element engaging feature contacts, the remaining of said second element engaging feature splines being spaced apart from the remaining of said first element engaging feature splines. 11. A construction toy according to claim 9, configured such that when said second element engaging feature splines are brought into said recess (30) and some of said first element engaging splines are forced When said inner surface of said second element engaging feature splines is engaged with said inner surface of some of said second element engaging feature splines, at most two of said second element engaging feature splines are each substantially aligned with said first element engaging feature splines. Only one of the splines of an element engaging feature contacts, the remaining of said second element engaging feature splines being spaced apart from the remaining of said first element engaging feature splines. 12. A construction toy according to any one of claims 2 to 11, wherein the first element engagement feature spline is shorter than the second element engagement feature spline. 13. A construction toy according to any one of claims 2 to 12, wherein said first element engagement feature closest to said first element engagement surface (14) is splined from said first element Said first element engagement feature furthest from the engagement surface (14) is splined short. 14. A construction toy according to any one of claims 12 to 13, wherein the second element engagement feature closest to the second element engagement surface (24) is splined from the second element Said second element engagement feature spline length and/or width furthest from the engagement surface (24). 15. A construction toy according to any one of the preceding claims, wherein: said element of said construction toy has an exterior wall; and The engagement surface (14, 24) is provided on the outer wall. 16. The construction toy of claim 1, wherein: The first element engagement surface (71) is disposed on a first engagement feature spline (54, 62) extending from the first element (10); said second element engaging surface (73) is disposed on a second element engaging spline (64, 70) extending from said second element; The first element engagement feature (75) is disposed in the region between additional first element engagement feature splines (56, 58, 60); and The second element engagement feature (77) is the end of a push spline (66A, 68A) extending from the second element (12) for pushing against the first element engagement feature (75). 17. A construction toy according to claim 16, wherein said second element pushing splines (66A, 68A) are smaller than said splines (64, 70) defining said second element engagement surface (73) long splines. 18. A construction toy according to any one of claims 16 to 17, wherein said first element engaging splines (54, 62) comprising said first element engaging surface (71 ) are larger than said additional The first element engaging feature splines (56A, 58A, 60A) are long and/or wide. 19. A construction toy according to any one of claims 16 to 18, wherein said first element splines (54, 56, 58, 60, 62) are spaced a greater distance apart than said second element splines (52, 64, 66A, 68A, 70, 42) are wide. 20. A construction toy according to any one of claims 16 to 19, wherein said first engagement feature splines (54, 62) comprising said first element engagement surface (71 ) A component engaging surface (71) is wider in area than the other of said first component engaging splines (56A, 58A, 60A) such that said first component engaging splines (54, 56A, 58A, 60A, 62A) are forced to ) between said second element engaging splines (52, 64, 66A, 68A, 70, 42) causes said engaging surface (71) of said splines (54, 62) to engage said spline Said engagement surfaces (73) of (64, 70) are biased into frictional engagement with each other. 21. A construction toy according to any one of the preceding claims, wherein a protrusion (40) extends above the second element engagement surface (24); and the second element engagement feature splines from The protrusion (40) extends. 22. A construction toy according to claim 21, wherein said recess (30) and said protrusion (40) are complementary in shape. 23. A construction toy according to any one of claims 21 to 22, wherein the recess (30) is concave in cross-section and the protrusion (40) is convex in cross-section started. 24. A construction toy according to any one of claims 21 to 23, wherein the recess (30) and protrusion (40) are arcuate in cross-section. 25. A construction toy according to any one of the preceding claims, further comprising a third element (80) for engaging the first element (10), the third element (80) comprising a mandrel (82) and a plurality of splines (84) extending from said shaft (82) for at least one said engagement feature (16) of said first member (10) ) engagement. 26. A method of making a construction toy as claimed in any one of claims 2 to 25, said method comprising the steps of: constructing injection molds for the elements of said toy; configuring the mold such that an injection point for the fabrication material is adjacent to a feature of the mold that defines the spline such that in the finished element the injection point is adjacent to the base of the spline or substantially at the top of the spline . 27. A construction toy substantially as hereinbefore described and/or as shown in Figures 7 to 25 of the accompanying drawings. 28. A method of making a construction toy substantially as hereinbefore described and/or as shown in Figures 7 to 25 of the accompanying drawings.