Note: Descriptions are shown in the official language in which they were submitted.
2051905
CONSTRUCTION TOY
Backqround and Summary of the Invention
The present invention is directed to construction
toys, and more particularly to a novel and improved form of
construction toy, comprising hub-like connector elements
and strut-like structural elements adapted to be removably
engaged with the connector elements to form a composite
structure.
A variety of construction toys is known, which are
comprised of combinations of connector elements and struc-
tural elements which can be combined in various forms toform composite structures.
The device of the present invention, while being of
a known general type, incorporates a variety of unique and
advantageous features which greatly enhance its perform-
ance. At the same time, the device is designed to be massproduced by injection molding techniques, so as to be
capable of manufacture on a low cost basis.
A hub-like connector element is provided with a
plurality of generally radially oriented sockets for
receiving and loc~ingly engaging end portions of typical
structural elements of strut-like configuration. The
connecting sockets are designed to accommodate lateral
snap-in insertion of the structural elements. The end
extremities of the structural elements are formed with an
annular groove, defining a flanged end. The sockets on the
connector elements are defined by spaced pairs of gripping
arms, and each arm includes an inwardly protruding locking
projection arranged to be received in the annular groove of
the structural element. Accordingly, upon lateral snap-
205190~
in installation of a structural element, it is lockedagainst axial withdrawal from the connector element.
The strut-like structural elements, molded to be of
circular cross section at the ends, are configured, in
regions intermediate the ends in a generally X-shaped cross
section. The X-shaped cross section is arranged for
cooperation with the opposed locking projections of the
gripping arms such that, when the structural element is
oriented at 90~ to its "normal" radial orientation in the
connector element, it may be pressed laterally between a
pair of gripping arms and snapped into locked position,
with the locking projections engaging the X-shaped cross
section to immobilize the structural element.
Among the structural possibilities enabled by the
last mentioned feature of crosswise gripping of structural
elements is the assembly of articulated belt-like struc-
tures, which can be incorporated into dynamically operated
toy structures, such as bulldozers, tanks, conveyor belts
and the like, and also static structures such as catenary
suspension elements.
One form of connector element enables one connector
to be joined with another, in planes which are disposed at
right angles to each other. A pair of thus-joined connec-
tor elements provides for an assemhly with structural
elements in two principal planes. In addition, each of the
available sockets still retains the ability to lockingly
receive structural elements oriented at right angles to the
principal plane of the hub-like connector element. In one
modification, an assembly of connector elements can be
provided which accommodates the mounting of strut elements
extending in four planar directions from a central axis.
Modified forms of such connector element assemblies are
provided in which strut elements extend in three planar
2051~0~
directions (forming a Tee-shaped joint) or in two planar
directions (forming a right angular corner joint).
The design and construction of the socket-forming
recesses, on the one hand, and the ends of the strut
elements, on the other hand, advantageously is such that
the cooperative action of the rib and groove means serves
to yieldably urge the strut elements axially into tight end
face contact with the end wall of the recess. This pro-
vides for a significant degree of additional stability in
the connection between the strut and connector.
To particular advantage, the construction toy system
includes a series of struts of graduated lengths, graduated
in accordance with a predetermined formula such that when
two struts of a given length in a series are joined with
-- 15 connector elements to form a right angularly related
structure, the strut of the next larger length in the
series is of an appropriate length to be joined in the
assembly along the hypotenuse of the triangular structure.
In this manner, a large structural assembly may be formed
utilizing rigid triangular structural subassemblies of
various different sizes for maximum strength and rigidity.
In the new system, in which a series of strut ele-
ments of graduated lengths is provided according to the
before- mentioned principle, a structure consisting of a
pair of like strut elements of a given length in the
series, mounted on opposite sides of a connector element so
as to be coaxial, are equal in length to the length of a
strut element two sizes larger in the series. This ar-
rangement provides for an extraordinary degree of flexibil-
ity in the arrangement of structural parts in any assembly.
CA 020~190~ 1997-11-24
A significant aspect of the foregoing geometric
relationship is the fact that the strut elements can be
assembled with the connector elements by lateral snap-in
assembly, so that the center to center distance of a pair of
connector elements does not have to be enlarged in order to
receive a strut element. This enables a structure to be
easily added to and/or modified even after it has reached a
stage of substantial rigidity.
For many dynamic structures, a driving relationship
between a strut element, functioning as an axle, and an
associated connector element may be desired. To this end, the
construction toy system incorporates a drive element
comprising a socket-forming recess of the type described,
which is intended for the crosswise reception of a strut
element functioning as an axle for an adjacent connector
element. The drive element is formed with a laterally
extending drive pin arranged to be received between adjacent
spoke-like webs of a connector element, in order to lock the
connector element in driving relation to the strut on which it
is supported.
For a more complete understanding of the above and
other features and advantages of the invention, reference
should be made to the following detailed description of
preferred embodiments and to the accompanying drawing.
Thus, as embodied and broadly described herein, the
present invention provides: Aconstruction toysystem of the
type comprising a plurality of connector elements and a
plurality of structural elements adapted to be removably
engaged with said connector elements to form a composite
structure, wherein
CA 020~190~ 1997-11-24
-4 a-
(a) each connector element having at least one open-ended
socket for receiving and retaining a strut-like structural
element by its end,
(b) each said socket having an inner end wall and a pair of
spaced-apart gripping arms defining an axis extending between
said gripping arms,
(c) integral locking projection means extending inwardly from
at least one of and preferably both of said gripping arms,
(d) said locking projection means being spaced from said
inner end wall and defining with said end wall a first locking
chamber,
(e) said gripping arms being formed with concave grooves
therein extending from said locking projection means toward
the open end of said socket,
(f) said concave grooves being generally coaxial with said
axis, and an opposed pair of said grooves defining a second
locking chamber,
(g) at least one end portion of said structural elements
being shaped to be confined within a generally cylindrical
envelope,
(h) said end portion defining an axis of said structural
element and having a locking flange at the end extremity,
receivable laterally within said first locking chamber and
being locked therein against movement in the direction of the
axis of said structural element,
(i) said end portion further having an annular groove
immediately adjacent and partly defining said locking flange,
(j) said annular groove being adapted to receive said locking
projection means when said structural element is inserted
laterally into said open ended socket,
(k) said concave grooves being shaped and positioned to
closely receive portions of the cylindrical envelope of said
structural element, and
CA 020~190~ 1997-11-24
-4 b-
~1) said gripping arms being elastically deflectable to
accommodate lateral insertion of said structural element into
said socket.
Description of the Drawinq
Fig. 1 is an elevational view, partly in section, of a
hub-like connector element constructed according to the
invention, with selected structural elements joined therewith.
Fig. 2 is a greatly enlarged, fragmentary, perspective
view of a portion of the connector element of Fig. 1.
20~1905
Fig. 3 is an enlarged, fragmentary view of the end
portion of a strut-like structural element constructed in
accordance with the invention.
Fig. 4 is a cross sectional view as taken on line 4-
4 of Fig. 3.
Figs. 5, 6 and 7 are sequential views, as taken
generally on line 7-7 of Fig. 1, showing progressive stages
of lateral, snap-in insertion of a structural element into
a socket of the connector element of Fig. 1.
Figs. 8 and 9 are enlarged, cross sectional views as
taken generally on lines 8-8, 9-9 respectively of Fig. 1.
Fig. 10 is an elevational view of a strut-like struc-
tural element constructed according to the invention.
Fig. 11 is a highly enlarged, fragmentary perspec-
tive view showing the structural element of Fig. 10 in-
stalled in a socket of a connector element at right angles
to the normal radial orientation.
Fig. 12 is a transverse cross sectional view as taken
generally on line 12-12 of Fig. 11.
Fig. 13 is a bottom perspective view of an adapter
block element, for integrating the construction toy with
certain popular, block-type construction toys.
Fig. 14 is an elevational view, partly in section,
of the adapter block of Fig. 13.
..
205 1 qO5
Fig. 15 is a top plan view of the assembly of Fig.
14.
Fig. 16 is a perspective view of an assembly of a
pair of modified connector elements each with the other.
Fig. 17 is an exploded view showing the component
elements of the assembly of Fig. 16.
Fig. 18 is a greatly enlarged, fragmentary perspec-
tive view of a connector element of Fig. 16.
Fig. 19 is an elevational view of the assembly of
Fig. 16.
Fig. 20 is an enlarged, fragmentary sectional view,
illustrating the manner in which a structural element of
Fig. 19 is inserted in certain of the sockets of the
connector element.
Fig. 21 is a side elevational view of a single socket
connector element constructed to receive one strut element
oriented axially in a socket-forming recess and a second
strut element in a hub bearing, disposed at right angles
thereto.
Fig. 22 is a side elevational view of a two element
connector.
Figs. 23-29 illustrate other modifications of connec-
tor elements.
Fig. 30 is a group view illustrating a series of
strut elements of graduated length and also the relation-
ship of the length of a given strut of a series to smaller
20~1~05
struts joined together coaxially by a connecting element.
Fig. 31 is a greatly enlarged view illustrating the
socket portion of a connecting element in cross section as
joined with a strut element.
Fig. 32 is an elevational view of an assembly of
strut and connector elements arranged in triangular sub-
units of increasing size.
Fig. 33 is a top plan view of an articulated belt or
tread structure constructed of a plurality of single unit
connectors and a plurality of strut elements mounted in
crosswise relation therein.
Fig. 34 is a cross sectional view as taken along line
34-34 of Fig. 33.
Figs. 35-39 are various views illustrating a modified
form of connector element which is capable of assembly with
a like connector element.
Figs. 40, 41 illustrate a connector element of the
type shown in Figs. 35-39, as assembled with a connector
element of the type shown in Figs. 16-20.
Fig. 42 is a perspective view of a drive element
constructed for crosswise reception of a strut element
serving as an axle, and provided with a driving lug.
Fig. 43 is an elevational view of the driving element
of Fig. 42, showing a strut element gripped in crosswise
relation therein.
20~19~
Fig. 44 is a view, similar to Fig. 43, showing in
addition a connector element received on the strut element
and drivingly engaged for rotation therewith.
Fig. 45 is an elevational view of a combined pulley
and wheel-forming element.
Fig. 46 is a side elevational view of a tire-like
element adapted for assembly with the element of Fig. 45.
Figs. 4~, 48 are cross sectional views as taken
generally on lines 47-47, 48-48 respectively of Figs. 45,
46.
Description of Preferred Embodiments
Referring now to the drawing, the reference numeral
designates a hub-like connector element 10, shown
particularly in Fig. 1. The connector element includes a
central hub cylinder 11 and radiating spokes 12. The
illustrated form provides for the connection of eight,
radially disposed structural elements, generally designated
by the reference numeral 13.
The radial spokes 12 support an array of eight
sockets 14, each comprising an end wall 15 and spaced-
apart, opposed gripping elements 16. The sockets 14 are
radially disposed with respect to the central axis 17 of
the connector, and the respective pairs of gripping ele-
~ ments 16 are desirably arranged on opposite sides of the25 radial axis of the socket, in generally parallel relation
to such radial axis.
The gripping elements 16 are provided in their outer
portions with concave grooves 18, which are concentric
about the radial axis 19 of the socket and extend from the
outer end extremities 20 of the gripping elements a suit-
. .
.. ,,, ., ,,, .. , . . , . . , ~ , . , ~, . . . .. .
205 1 905
able distance toward the base wall 15 of the socket,typically about halfway.
The strut-like structural elements 13 are of general-
ly cylindrical construction at the their end extremities.
The structural elements may have a nominal diameter of, for
example, approximately 0.250 inch, for cooperation with
concave grooves 18 in the gripping elements formed on a
diameter of the same dimension.
As is apparent in Fig. 5, the arc of the grooves 18
serves to narrow the entrance area 21 to a dimension
significantly less than the 0.250 inch diameter of the
structural element. The dimension at the throat or opening
21 may be on the order 0.210 inch. Accordingly, it is
desirable to form the lateral edges 22 of the gripping arms
to diverge from the throat 21 to the outer lateral surface
23 of the gripping arm. An angle of divergence of about 15~
is appropriate. This facilitates the lateral insertion of
the structural element 13 into the grooves 18 by causing
the gripping arms 16 to be laterally displaced and sepa-
rated. Once the structural element is seated in thegrooves 18, the gripping arms 16 close snugly about the
structural element to retain it in position.
Each of the gripping arms 16 is provided with a
locking projection 24, desirably of semicylindrical config-
uration, extending at right angles to the radial axis ofthe socket defined by the gripping elements. In the
illustrated construction, the projections 24 are of gener-
ally uniform cross section and extend from one side edge of
the gripping arms 16 to the other, as shown best in the
enlarged perspective view of Fig. 2.
205 1 935
--10--
The locking projections 24 are spaced radially
outward a short distance from the base wall 15 of the
socket and define therewith a flange-receiving recess 25 at
the inner or base end of the socket.
As shown in Fig. 3, the end extremity of each of the
structural elements 13 is configured such that a longitudi-
nal cross section of the end portion is approximately the
same as the longitll~;n~l cross section of a socket 14,
taken along its radial axis in a plane parallel to the flat
sides of the connector element. The structural elements 13
include cylindrical end flanges 26 of a size and shape to
be received in the flange recess 25 of the socket. Immedi-
ately adjacent the cylindrical end flange 26 is an annular
recess 27 of a semicircular cross sectional configuration
adapted to be received within the narrowed space between
opposed locking projections 24. Immediately adjacent the
annular groove 27 is a cylindrical gripping portion 28,
which is adapted to be received in the concave grooves 18
and gripped snugly by the outer portions of the gripping
arms 16. The axial length of the gripping portion 28
desirably corresponds to the effective length of the
grooves 18. The cylindrical flange 26 may have an axial
length of, for example, 0.062 inch. The annular groove 27
and the locking projections 24 may have a typical radius of
approximately 0.062 inch. For structural elements of 1/4
inch nominal diameter, a suitable length overall for the
gripping sockets 14 is about 0.35 inch.
A typical form of strut-like structural element 13 is
shown in Fig. 10. The element may of course be of any
length, and a typical construction toy set incorporating
principles of the invention would utilize large numbers of
such elements, of various appropriate lengths. To particu-
lar advantage, portions of the structural element between
205 1 905
--11--
its respective end portions 30 are of an X-shaped cross
sectional configuration, comprised of ribs 31, extending
radially, typically at 90~ angular intervals and preferably
with the external surfaces 32 of the ribs lying on the
cylindrical envelope of the element as defined by its
cylindrical end portions.
By properly dimensioning the thickness 33 of the ribs
31, and slightly beveling the outer sidewall portions
thereof, as indicated at 34, the structural element is able
lo to be pushed laterally into the open end of a radial socket
14 and forced between a pair of opposed locking projections
24, as reflected in Figs. 11 and 12, seating the projec-
tions in recesses 39 between adjacent ribs.
The X-shaped cross section of the structural element
may be periodically interrupted by one or more pairs of
cylindrical portions 35 spaced apart a distance approxi-
mately equal to the width dimension 36 of the gripping arms
16. When the structural element is snapped into locked
position on the projections 24, as shown in Figs. 11 and
12, the structural element is locked in position axially,
laterally and rotationally. Alternatively, if the struc-
tural element is applied laterally into the radial socket
14 in one of its areas 37 in which adjacent cylindrical
sections 35 are widely spaced, it is possible to adjust the
position of the structural element along its axis, within
limits.
In a specifically advantageous embodiment of the
invention, the width of the ribs 31 may be on the order of
0.093 inch, tapered convergently in the outer portions, as
is reflected particularly in Fig. 4. It will be understood
that "X-shaped" configuration of the structural elements 13
is not limited in principle to the use of two pairs of
2 a ~
ribs. For example, three pairs of ribs may be arranged at
60~ angular spacing. Accordingly, the term "X-shaped", as
used herein is to be interpreted as encompassing such
alternatives.
As reflected in Figs. 13-15, the present invention
provides an adapter element, generally designated by the
reference numeral 40, of block-like configuration, which is
adapted to interface between conventional block-type
construction elements and the construction toy elements of
the present invention.
In Figs. 14 and 15, for example, elements 41, 42 are
block-like construction elements of a known type, con-
structed in the form of an open-sided block provided with
a "top" wall 44 and sidewalls 45-48 forming an open cavity
49. The top wall 44 is provided with a plurality (eight in
the illustration) of short circular projections 50. Also
extending from the top wall 44 through the cavity 49 are
three elongated tubular friction posts 51. In accordance
with known design of the block-type construction elements
41, 42, the internal dimensions of the cavity 49 are such
as to fit snugly about the external projections 50. In
addition, the friction posts 51 are dimensioned to have
tangential contact with the sides of t~e projections 50
when construction blocks are placed one atop the other.
This enables, in a known manner, the plurality of construc-
tion blocks to be frictionally assembled to form a compos-
ite structure.
The adapter block 40 includes a "top" wall 52 and
sidewalls 53. In the illustrated arrangement, the adapter
block is of square configuration, but other configurations
are possible within the contemplation of the invention.
Projecting from the top wall 52 are four elongated cylin-
, .. , , . .. , .. _ . , .
205 ~ 905
-13-
drical projections 54 of a diameter and spacing correspond-
ing to the short circular projections 50 of the construc-
tion blocks 41, 42. These cylindrical projections 54 may
be inserted into the open cavity 49 of a construction block
and desirably are of a length corresponding generally to
the depth of the cavity 49.
A tubular adapter sleeve 55 extends from the under-
side of the "top" wall 52, through the open cavity 56 in
the adapter block. The internal diameter of the tubular
sleeve is such as to snugly receive an end portion 30 of a
structural element 13, as shown in Fig. 14. The tubular
sleeve 55 is recessed below the open edge 57 of the adapter
block side walls so that the adapter block may be assembled
with a conventional construction block in an otherwise
known manner.
A connector element 70, shown in Figs. 16, 17, has
the general "snowflake" configuration of the device de-
scribed above, and has many of the structural features of
the before mentioned device, but is specially modified to
accommodate assembly with a second, similarly configured
connector element oriented at right angles thereto. The
connector element 70 is generally of a flat, open configu-
ration, typically about 1/4 inch in thickness. At its
center, the connecting element 70 has a solid, semi-cylin-
drical core 71. Guide walls 72, 73 extend from oppositesides of the core 71, in spaced-apart, parallel relation.
The spacing between the guide walls 72, 73 is substantially
equal to the thickness of the connector element, allowing
for a second such element to be received within the recess
74 defined by the spaced-apart guide walls 72, 73 and a
flat transverse wall 75 which forms one side of the core 71
and is positioned on an axial plane passing through the
connector element.
2051 905
-14-
Ext~n~;ng radially outward from the core are a
plurality of spoke-like elements 76-78 which, at their
outer ends, join with peripheral walls 79, 80. In the
illustrated arrangement, the walls 79, 80 define seven
sides of a generally octagonal structure, with the eighth
side being open to accommodate the recess 74. As is
evident in Fig. 17, the several walls 79 extend continuous-
ly from one spoke to the other (or from a spoke to the
guide walls 72, 73). The wall 80, which lies directly
opposite the recess 74 is, however, formed with a disconti-
nuity 81 the function of which will be explained hereinaf-
ter.
Each of the walls 79, 80 forms the end wall of a
strut-receiving socket 82 (in the case of the walls 79) or
83 (in the case of the interrupted wall 80). Each of the
sockets is defined by pairs of opposed gripping elements 84
provided internally with a semi-cylindrical locking projec-
tions 85, which extend at right angles to the generally
radial axis of the socket. The locking projections, in
conjunction with the base walls 79, 80, define flange-
receiving recesses 86. The outer portions of the gripping
elements 84 are formed with concave grooves 87 concentric
with respect to the generally radial axis 88 of the socket.
As shown in Fig. 19, strut-like structural elements
90 are provided with cylindrical end flanges 91, adjacent
annular grooves 92, and cylindrical portions 93 arranged to
be received snugly in the concave grooves 87 of the grip-
ping elements. The structural member 90 (sometimes re-
ferred to as a strut) normally is assembled with the
connector element 70 by being pressed laterally into one of
the recesses 82. The lateral entrance to the recess 82 is
partially closed by a narrow throat section, defined by
205 1 ~05
upper and lower edges 94 of the cylindrical grooves 87.
Divergent guide surfaces 95 are provided to facilitate
lateral insertion of the structural elements.
To particular advantage, the configuration of the
sockets and struts is such that, when a strut end is
received in a socket, the flat flange end wall 91a of the
strut is resiliently urged into firm face to face contact
with the flat base wall 79 (or 80) of the socket. This
arrangement adds significant stability and rigidity to an
assembly of parts. The desired relationship is achieved by
displacing the locking flanges 85 slightly in the direction
of the socket end wall 79, with respect to the "normal"
position of the strut groove 92. Thus, when the strut is
snapped into assembled position it is automatically pressed
toward the bottom of the socket to urge the flat walls 91a
and 79 into tight face to face contact.
With reference now to the exploded view of Fig. 17,
the reference numeral 70a designates generally a second
connector element, identical to the connector element 70,
but oriented so that its principal plane lies at right
angles to that of the element 70 and also so that its
recess side (not shown in Fig. 17) faces the recess 74 of
the element 70. When these two elements 70, 70a are moved
together, in the direction of the arrow 96, the portion of
the connector 70 to the left of the end surface 75 is
received by the recess of the connector element 70a.
Likewise, the recess 74 of the element 70 receives the
right-hand portion of the element 70a. The completed
assembly of the two connecting elements 70, 70a is evident
in the perspective view of Fig. 16. The assembled connec-
tors provide radially oriented strut-receiving recesses in
two planes, so that the structural possibilities of the
system are greatly enhanced.
211~1~0~
-16-
To secure the two connector elements 70, 70a in
assembled relation, cooperating ribs and grooves are formed
on the respective parts. The guide walls 72, 73 are
provided with transverse detent grooves 97. These are
arranged to receive appropriately located detent ribs 98 on
the opposite connector element. The ribs 98, as indicated
in Fig. 17, are formed on the radial spokes 77. During
assembly of a pair of connector elements 70, 70a, as the
projecting ribs 98 reach the outer end of the guide walls
72, 73, the guide walls are elastically displaced outwardly
a distance sufficient to accommodate the presence of the
ribs. This elastic displacement is facilitated by provid-
ing a small gap 81 in the recess wall 80. Thus, during the
assembly process, the opposite halves of the divided wall
are displaced toward each other, facilitating the
outward displacement of the guide walls 72, 73. This
process is happening simultaneously on both of the connec-
tor elements 70, 70a, as will be understood.
The single plane connector element described in Figs.
1-5 is formed with a symmetrical array of eight strut-
receiving sockets. The individual connector elements 70,
70a, on the other hand, are formed with one less strut-
receiving socket, by reason of the open-sided recess 74 at
one side of the connector. Nevertheless, when the two
elements are assembled, as reflected in Fig. 16, for
example, each connector element contributes, in effect, a
strut-receiving socket to the other connector element, so
that there are four pairs of opposed sockets in each plane.
When two of the connecting elements are assembled in
the manner of Fig. 16, three opposed pairs of sockets on
each connecting element are open and accessible for lateral
2051 qO5
insertion of a strut 90. However, in the case of one of
the opposed pairs of sockets, designated as 83, 83a, normal
lateral insertion of a strut is precluded by the immediate
adjacency of outwardly extending gripping elements 84
carried by the opposite connecting element of the assembly.
Insertion of a strut element 90 into the partially
inaccessible sockets 83, 83a is facilitated by reason of
the slotted recess wall 80. The slot 81 therein enables
limited outward displacement of the adjacent gripping arms
84 to enable a strut element to be "cammed" into position
through a levering motion, illustrated schematically in
Figs. 19 and 20.
With reference to Fig. 19, the position of the strut
90 shown in broken lines represents a typical starting
position for inserting a strut into a socket 83a of a
connecting element 70a. The end surface lO0 of the strut
is placed against an outer surface 101 of the adjacent
gripping arm, and this serves somewhat as a guide as the
strut is pushed laterally into the socket, while generally
holding the angular orientation shown in Fig. 19. During
this operation, there is an initial outward displacement of
the opposed gripping arms, accommodated by the slot 81
which tends to open up wider than normal. In addition, the
recess guide wall 72 is deflected outward slightly, and
this is encouraged by a levering action of the strut 90 in
the direction of the arrow 102 of Fig. 19. This has the
effect of prying upwardly against the guide surface 101, so
that the adjacent gripping arm 84 is displaced in the
direction of the arrow 103 in Fig. 20. Levering of the
strut continues until the flanged end of the strut snaps
into place in the recess, as shown in full lines in Fig.
19. Removal of a strut from one of the partially blocked
205 1 905
-18-
recesses 83 or 83a is accomplished by a generally reverse
procedure.
As shown in Fig. 31, the configuration of the socket-
forming recesses 150 and struts 140 advantageously are such
that the center of curvature of the ribs 130, 131 is
located on an axis 151 which is offset from the surface 152
of end wall 125 a distance slightly less than the offset
between the axis 153, containing the center of curvature of
the annular groove 147, and the end surface 154 of the
strut element. As a result, when the strut element is
forced laterally between gripping arms 126, 127 into
gripped position in the recess 150, the ribs 130, 131 are
in pressure contact with side portions of the annular
groove, in a manner to force the strut end surface 154 into
tight face-to-face contact with the surface 152 of the
recess end wall. By tightly holding these two surfaces in
face-to-face contact, a desirable degree of additional
rigidity is imparted to the assembly of the strut and
connecting element.
Connector elements may be formed in a wide variety of
types and styles, having from one to a plurality of socket-
forming recesses 150. Connector elements having more than
one recess advantageously are configured so that recesses
are separated angularly by 45~, or a multiple thereof,
although other configurations are useable within the
teachings of the invention.
In Fig. 21, a single recess connector element 160 is
illustrated. It includes a hub section 161 defined by a
cylindrical wall 162. The inside diameter of the hub
cylinder is approximately the diameter of a cylindrical
envelope formed by the strut elements 140. The diameter of
that cylindrical envelope corresponds to the diameter of
the cylindrical end portions 146, 148 of the strut element,
and also to the diametric dimensions of the ribs 145. A
205 1 905
--19--
strut element thus may be freely received in the cylindri-
cal opening 163 of the hub, with a slight clearance to
accommodate free rotation and free longit~;n~l movement of
the struts within the hub cylinder. The axis 164 of the
hub cylinder is disposed at right angles to the longitudi-
nal axis 165 of the recess 150. The wall 167, which forms
the end wall of the recess 150, is spaced from the hub axis
164 by a pair of space web sections 166, which are integral
with the wall 167 and the hub cylinder 162.
Typically, the connector elements are constructed of
a predetermined, uniform thickness in the direction of the
hub axis 164. Preferably, the width is approximately equal
to the diameter of the cylindrical envelope of the strut
elements. A thickness of approximately 0.244 inch has been
found to be particularly desirable, in that it permits, in
most cases, connector elements to be assembled side-by-
side, cross-ways with respect to a strut, over the full
length of the central body of the strut, with virtually no
space left at either end. This allows structures to be
formed with, in effect, a solid wall of elements joined to
a transversely disposed strut across the full width of the
body portion of the strut.
The connector device illustrated in Fig. 22 is
similar to that shown in Fig. 21, but includes a pair of
socket-forming recesses 150 angularly separated by 180~,
with the longitudinal axis of the respective socket-forming
recesses being coaxially aligned and intersecting with the
hub axis 172. The connector element of Fig. 22 is particu-
larly useful for joining a pair of strut elements end to
end, in coaxially aligned relation, as reflected in Fig.
30. For this and other reasons, the distance from the hub
axis 172 to the outer face of the recess end wall (corre-
sponding to the surface 152 in Fig. 31) is the same for
2051 905
-20-
both recesses of the connector element 170 of Fig. 22 as
for the single connector element 160 of Fig. 21. This
difference is designated by the letter "d" in Figs. 21 and
22. This geometric relationship is also applied to the
several varieties of connector elements illustrated herein
such that, in all cases, a strut element secured in a
socket-forming recess of a connector element is positioned
a fixed, predetermined distance from the central hub axis
of the connector element.
In the illustration of Fig. 23, a connector element
180 is shown, which also is provided with two socket-
forming recesses 150. These are aligned along axes 181
intersecting with a hub axis 182 disposed at right angles
thereto. The construction of the hub cylinder, recesses
150, etc. is generally the same as described with respect
to the connector elements 160 and 170. However, in the
modification of Fig. 23, the strut-receiving recesses 150
are spaced apart by an angle of 45~.
In the connector elements 190, 200 of Figs. 24 and 25
respectively, the connector elements are provided with
three and four strut-receiving recesses 150 respectively,
in each case arrayed along axes 191, 201 intersecting with
a hub axis 192, 202 and angularly spaced 45~ apart. As
reflected in the views of Figs. 23-25, the connector
elements therein shown include intermediate, radially
disposed spoke-like walls 183, 193, 203 which extend
radially with respect to the hub axes 182, 192, 202 and are
joined integrally with end walls of adjacent recesses 150.
The outermost walls 184, 194, 204, on the other hand,
extend into tangency with the respective hub cylinders 185,
195, 205.
. ~
2051~0~
-21-
In the illustrations of Figs. 26-28 connector ele-
ments 210, 220, 230 are formed to have, respectively, five,
six and seven socket-forming recesses 150, each arrayed
along an axis intersecting and extending radially from the
hub axis 212, 222, or 232. The several recess axes 211,
221 and 231 are spaced apart at an angular distance of 45~,
as in the case of the connectors of Figs. 23-25. Prefera-
bly, in each of the connector elements of Fig. 26-28, the
exterior wall sections 214, 224, 234 are arranged to be
tangent to the hub cylinders 215, 225, 235, for both
esthetic and functional purposes. The wall; 214 of the
connector element 210, for example, in conjunction with the
continuing wall of the associated socket-forming recess,
provide a broad, flat surface on which to support the
connector element and/or a flat surface to define an outer
edge of a structure.
., .
The connector element 240 of Fig. 29 is substantial-
ly of the configuration shown in Fig. 1, in this instance
being formed as part of a series of connector elements of
common dimensions. In this respect, the distance "d" from
the hub axis 242 to the face of any recess wall is the same
uniform distance as in the other illustrated forms of
connector elements.
l~ith reference to Figs. 30 and 32, the system of the
invention advantageously incorporates strut elements in
various graduated lengths, according to a predetermined
size progression, such that strut elements of various sizes
in a set may be assembled together with the before de-
scribed connector elements to form a series of right
triangular structural units of an assembly. In the compos-
ite illustration of Fig. 30, there are shown a series of
strut elements 140a-140f, inclusive, of progressively
increasing lengths. The progression of lengths is such
2051 905
-22-
that when any two strut elements of a given size are joined
with a connector element to form two sides of a right
triangle, the strut of the next greater length is of the
appropriate size to form the hypotenuse of that triangle.
For example, in Fig. 32, a three-position, right angle
connector element 190 is joined with two strut elements
140a of the smallest size, forming the sides of a right
triangle. In the illustration, the vertically oriented
strut 140a is joined with a four-position connector element
200 and the horizontally oriented strut element 140a is
joined with a five-position connector element 210. A strut
element 140b, constituting the next size longer than the
strut elements 14Oa, is joined with the connector elements
200, 210, forming the hypotenuse of a small right triangle.
In the illustration of Fig. 32, the element 140b,
which forms the hypotenuse of the first described right
angular structural element, designated by the reference
numeral 250, itself forms one side of a right triangular
structural element 260 of a larger size. In this respect,
the connector element 200 is joined with a second strut
element 416 of the same length as the strut 140b to form
two sides of the triangle 260. A second four-position
connector element 200 is joined to the upper end of the
upper strut element 416, and a strut element 140c, being
the third element in the length progression, is joined with
the upper connector 200 and the before mentioned connector
210 and constitutes the hypotenuse of the triangular
structural element 260. As is evident in Fig. 32, a pair
of the strut elements 140c may in turn constitute the sides
of a still larger right triangular structural unit 270, the
hypotenuse of which is constituted by the next larger size
strut element 14Od. Progressively larger right trian-
gular structural units may
205 1 905
-23-
be assembled, within the limits of the maximum length strut
element provided by the set.
In the system of the invention, the length progres-
sion of the strut elements is in accordance with a prede-
termined formula. Thus, in a system of "n" differentlengths, each strut length is determined according to the
formula:
Lx = (1.414)~) * Dmjn ~ (2 * d), where
Lx = Length of the x~h strut of a series of 1 to "n",
Dm,n = the spacing between hub axes of two connector
elements joined by the shortest strut element of the
series,
d = the distance from the hub axis to the end wall of
the socket-forming section.
It is known to assemble structures of right triangu-
lar units, including structures in which the hypotenuse of
one triangular unit constitutes a side of a second and
larger right triangular unit. In the toy system of the
present invention, however, unique advantages are derived
from the design of the connector elements and strut ele-
ments to accommodate lateral, snap-in assembly of the strut
elements into the connectors. This enables parts to be
assembled and disassembled from the structure, without
involving change of the center-to-center distances between
connector elements and connection points. Thus, complex,
rigid, multi-dimensional structures can be designed and
assembled for great facility.
As shown in Fig. 30, there is also an advantageous
geometric relationship between the graduated length strut
elements 140a-140f and connector elements in which there
are socket-forming recesses oriented 180~ apart. This
includes in particular the connector element 170 (Fig. 22),
205 1 905
which is a two-position connector element having its
recesses 150 coaxially aligned and oppositely facing. This
connector element serves usefully as a splicing connector,
to join two shorter strut elements to form a longer strut
assembly. When one of the connector elements 170 (which
may conveniently be referred to as a splice connector) is
joined with two struts of a given size, a strut assembly
is formed which is equal in length to a strut two sizes
larger than the strut elements joined by the splice connec-
tor. Thus, as shown in Fig. 30, two of the shortest strutelements 140a are spliced to form a strut assembly equal in
length to the strut 140c. Two of the next size strut
elements 140b are spliced to form a strut assembly equal in
length to the strut 14Od. Additional corresponding assem-
blies are shown in the composite view of Fig. 30. It ispossible, of course, to join in a splice connector 170
strut elements of different lengths, in order to develop
strut assemblies of a length different from the standard,
progressive strut length illustrated in Fig. 30.
Since all of the connector elements, regardless of
configuration, employ a common spacing "d" from hub axis to
the end surface of the socket-forming recess, the relation-
ships illustrated in Fig. 30 will be true in any situation
in which strut elements are assembled to a connector with
a coaxial orientation.
The assembly shown in Figs. 33 and 34 is comprised of
a plurality of single recess connector elements 160 (Fig.
21) joined with a plurality of strut elements of a prede-
termined uniform size, such as elements 140c as reflected
in Fig. 30. A first plurality (three in the illustration)
of single unit connector elements 160 are arranged in side-
by-side relation, spaced apart by the width of a connector
element, and are rotatably connected
20~190~
to a strut element, as designated by the reference numeral
280 in Fig. 34. The strut element 280 is passed through
the hub opening 281, in which it is freely received. For
purposes of identification, the reference numeral 282 is
applied to connector elements of the first group. Alter-
nating with the connector elements 282 are similar connect-
ing elements, identified by the reference numeral 283. The
connector elements 283 are snap fitted onto the strut
element 280, with the rib portions 130, 131 of the connec-
tor element tightly received in the grooves 144 of thestrut element, so as to tightly grip the strut element.
Thus, while the individual connector elements 282 are
freely movable with respect to the strut element 280, the
alternating connector elements 283 are rigidly secured
thereto, both against rotation and sliding movement. A
succession of such assemblies provides an articulated belt-
like structure, which can be endless in form or of finite
length, as desired, and can be of any suitable width for
the purpose intended. As shown in Fig. 33, the end extrem-
ities of the strut elements project a short distance fromeach edge of the belt-like assembly.
Structures of the type shown in Figs. 33, 34 have a
wide variety of advantageous uses. Among these is the
formation of tracks, for track-laying vehicles such as
bulldozers, cranes, tanks and the like. Panel-like struc-
tures can also be assembled to function, in a toy struc-
ture, as wall or roof panels, for example, floor surfacing
and the like. A narrow assembly can be utilized as a
flexible cable-like element, for example.
With reference now to Figs. 35-~1, there is shown a
particularly advantageous form of connector element ar-
ranged for assembl~v with another connector element having
similar features, to provide a connector assembly providing
2a~ls~
-26-
means for joining strut elements extending in a plurality
of planar directions.
The connector elements 310 illustrated in Fig. 35 are
formed with four recess positions 150, angularly spaced at
45~. Directly opposite one of the recess positions 150a of
each element is positioned a special recess 311. The
recess 311 is defined by spaced-apart side walls 312, 313
and a bottom wall 314. The side walls 312, 313 are spaced
apart a distance equal to the standard th ckness of a
connector element and are arranged symmetrically to an
imaginary plane extending through the geometric center of
the connector element 310 and containing the longitudinal
axis of the oppositely oriented strut-receiving recess
150a. The exposed surface of the end wall 314 lies on a
plane at right angles to the previously mentioned plane,
also passing through the principal axis of the connector,
identified by the reference numeral 315.
The connector elements 310 are arranged to be assem-
bled together in the manner reflected in Figs. 35-37, with
the respective special recess portions 311 facing each
other and the principal planes of the respective connectors
being oriented at right angles. The respective connectors
310 are pressed together until the end walls 314 of the
recesses 311 are in firm face-to-face contact, so that the
respective central axis 315 of each element lie substan-
tially in a common plane.
Desirably, each of the recess walls 312, 313 is
formed with a transverse groove 316 arranged to receive, in
detent locking relation, ribs 317 projecting from opposite
sides of spoke walls 319. Accordingly, when the two
elements are assembled together, they ar~ relatively
2051 905
-27-
rigidly locked together against any but intentional separa-
tion.
As reflected in Fig. 36, when the walls 312, 313
first engage the projecting ribs 317, the walls are dis-
placed outwardly. The presence of a small gap 318 enablesthe gripping arms of the opposed strut-receiving recess
150a to be easily displaced toward each other while the
walls 312, 313 are being outwardly displaced by the ribs
317. When the parts are pressed together to their final
positions, with the end walls 314 seated against each
other, each of the sets of ribs 317 will be seated in each
of the sets of grooves 316, substantially as shown in Fig.
37.
The assembled connector elements of Figs. 35-39
provide for the support of strut elements in each of two
planar directions disposed at right angles. The connector
arrangement thus is perfectly suited for assembling exter-
nal corners of structures, as can be appreciated by obser-
vations of Figs. 38 and 39.
In the composite view of Fig. 40, a connector element
310 of the type shown in Figs. 35-39 is arranged to be
joined with a second, seven-position connector 410. The
connector element 410 includes a special recess 411 dis-
posed coaxially opposite to a strut-receiving recess 150a.
Assembly of the connector elements 310, 410, to form
a multi-planar assembly is accomplished in the same manner
described with respect to Figs. 35-39. The resulting
assembly is of Tee-shaped configuration when viewed from
above, as reflected in Fig. 41, and provides for the
mounting of strut elements in each of three planar direc-
tions. In the Tee-shaped assembly of Figs. 40, 41, the
20~i190~
-28-
upper socket position 150a is not accessible for normal,
lateral snap-in assembly of a strut element, because of the
presence of the associated connector element. However, by
providing the gap 318 in the recess end wall, it becomes
possible to insert the strut initially at an angle and to
install it by a twisting motion, all as hereinbefore
described. The gap 318 allows the gripping arms 16 to more
easily separate, in order to accommodate a twist-in assem-
bly of the strut.
For certain applications, however, it may be desired
to lock a connector element together with a strut passing
through its central hub opening, for rotation in unison
and/or for fixing the position of the connector element
axially along the strut element. To this end, the system
includes a drive element, such as illustrated in Figs. 42-
44 of the drawing, for frictionally and non-rotatably
gripping a strut element. In the illustrated form, the
drive element comprises a drive block 510, injection molded
of suitable plastic material and advantageously incorpo-
rating a socket-forming recess 150 of the form previously
described. This includes particularly the opposed project-
ing ribs 130, 131 defining a narrow throat area between the
gripping arms 16. Adjacent the closed end of the recess
150, the block 510 advantageously mounts a driving lug 511
projecting laterally fro~ one end face 512, generally
parallel to the alignment of the ribs 130, 131.
In a typical utilization of the drive block 510, a
connecting element 240, typically of a full "snowflake"
configuration, having eight strut-receiving positions, is
mounted on a strut 513. The drive block 510 is applied to
the body portion of the strut 513, so that the respective
ribs 130, 131 are received in and lockingly engaged with
opposed longitudinal grooves 144 of the strut. The block
2a~lso~
-29-
510 is thus rigidly fixed to the strut against rotation and
also is frictionally restrained against longitudinal
movement along the strut (being slidable therealong,
however, under appropriate force).
The location of the drive lug 511 is such that, when
the connector element 240 and drive block 510 are directly
adjacent each other, the drive lug 511 is posit ioned in and
substantially occupies the trapezoidal space between a pair
of adjacent, radially disposed spoke-like walls 123. The
strut 513 and connector element 240 are thus locked against
relative rotation, so that rotational drive applied to one
of the elements is correspondingly imparted to the other.
By positioning drive blocks 510 on opposite sides of a
connector element, the connector element can be locked in
position, axially on a strut.
For many dynamic toy assemblies, drive pulleys and/or
wheels are useful and desirable elements. To advantage, a
combined pulley/wheel element 610 is shown in Fig. 45.
This is an injection molded part formed with an outer rim
611 and a central hub opening 612 adapted to be closely
received over a strut element. Radially outward from the
central opening 612 are one or more drive recesses 613.
These are arranged to receive the drive lug 511 of a drive
block (Fig. 42). As shown in Fig. 47, the element 610 is
provided with an external annular recess 614, which enables
the element to function as a pulley, when associated with
an appropriate drive belt (not shown). When the element
610 functions as a pulley, it is drivin~ly connected to a
strut element, using a drive bloc}; 510, funct oning either
as a drive pulley or a driven pulley, as the case may be.
The element 610 can be covered to form a wheel by
applying the tire element of Fig. 46. The tire element,
20~1905
-30-
designated generally by the numeral 620, is formed of a
resilient elastomer, such as neoprene. The inner portion
621 of the tire is of a width to be closely received in the
annular recess 614. The outer portion 622 of the tire is
wider than the inner portion 621, advantageously equal in
width to the thickness of the outer rim portion 611 of the
wheel element 610. Shoulders 623 are formed at each side
of the tire. These engage outer flanges 624 of the wheel
element 610, to position the tire concentrically on the
supporting rim.
When used as a wheel, the element 610 may be driven
or not, as desired. If it is to be driven, then a drive
block 510 is employed, as previously described.
The construction toy system of the invention provides
a uniquely simplified, yet exceptionally versatile con-
struction medium, for assembling a limitless variety of
structures, both static and dynamic in character. The
system easily lends itself to the production, by economi-
cal, mass production injection molding techniques of
standardized building elements of a wide variety, permit-
ting the relatively quick and simplified assembly of
structures.
Within the basic concepts of the invention, it is
possible to construct simplified and effective forms of
dynamic structures, such as endless tracks or helts, driven
rotating systems and the like. These are achieved with the
consistent use of standardized strut elements and standard-
ized connecting elements. That is, the connecting elements
utilize standardized socket-forming recesses, although
various in number, and such recesses are located at stan-
dardized distances from the principal axis of the connect-
ing element. Likewise, the strut elements incorporate
2051 935
-31-
st~n~rd end configurations, in conjunction with body
portions of various length. Further, by providing for a
splice connector, capable of joining two strut elements end
to end, the structural combinations available from a
relatively limited number of standardized strut lengths is
multiplied.
The elements of the construction toy of the invention
are adapted readily for high production injection molding
of the component parts of a suitable plastic material. A
variety of such plastic materials are suitable for the
purpose, it being necessary, of course, to select a materi-
al having a reasonable degree of strength and elasticity to
enable proper functioning of the gripping arms, for exam-
ple, over numerous assembly and disassembly operations. A
material known to be suitable for the purpose is "Celcon
M270", an acetal copolymer made available by Hoechst
Celanese, Chatham, New Jersey.
By enabling the hub-like connector elements to be
joined with structural elements by a lateral snap-together
action, it becomes more practical to assemble large and
complex structures, because the center-to-center distance
between component elements does not have to be altered
during joining of the components. By contrast, where
assembly of the components requires axial insertion of one
2S part into another, center-to-center distances are tempo-
rarily enlarged, which at best requires great care and at
worst may make it impossible to assemble certain types of
structures.
The arrangement of the invention provides a unique
two-way gripping action between the hub-like connector
elements and the structural elements, wherein the outer,
deflectable portions of the gripping arms provide
205 1 905
-32-
lateral containment, while the innermost portions of the
gripping arms form a relatively non-deflectable flange-
receivingcavity which freely admits the end flange of the
structural element during lateral assembly, but provides
positive restraint against axial movement of the structural
element.
