Note: Descriptions are shown in the official language in which they were submitted.
CA 02361993 2003-02-27
2003Feb27
Patent Application of
Benjamin I. Wiens and Eric G. McIntosh
for
SNAP-FIT CONSTRUCTION SYSTEM
B ACKGROUND-Field
The invention relates to modular construction systems that have releasable
snap-fit connection el-
ements that are actually interlocking features of the construction elements
themselves, which can be
integrated into many differently shaped construction elements and be useful in
a variety of fields.
BACKGROUND-Prior Art
Construction systems incorporating various methods of connecting construction
elements to-
gether are known in the art. Many construction elements connect primarily on
one or two faces. One
construction toy that connects on two faces is the brand "Lego Classic," shown
in U.S. Patent No.
3,005,282. A stud and friction-fit type of connection is used on what are
generally considered to be the
top and bottom faces of a construction block. This type of connection system
is deficient however, as
these blocks may not be connected on the other faces, such as side-to-side in
a single layer in order to
create a span, or overhang, or to construct a beam projecting outwards. Such
blocks can be inexpen-
sively produced with simple plastic injection molds. The same studs could be
added to more faces,
however this would result in more expensive production.
Construction elements with connection elements on more than two faces have
been developed.
The most common form seen in toys is of the brand "Lego Technic," which uses
studs and cavities on
the top and bottom faces, and through-holes projecting through two of the
remaining faces of block
CA 02361993 2003-02-27
and beam construction elements. Snap-fit pins pushed through the holes can be
used to connect two or
more construction elements together. Such construction elements require more
expensive molds to
produce than the "Lego Classic" type because the draw in the mold is in more
than one direction. Using
holes rather than extra studs and cavities results in more flexibility in
construction. Engaging many
construction elements together side-to-side with snap-fit pins is not
considered very practical
however.
a Another method of engaging construction elements together that is less
common in toys but more
popular in larger construction systems is the dovetail connection. For
example, U.S. Patent No.
2,619,829 by "Tatum" shows a hollow construction block, suitable for blocks
made of concrete, which
contains one fixed male, and one or more female dovetails in the side of the
block. A separate double
male connecter is also provided to connect two opposing female dovetails when
required. Such a sys-
tem can connect blocks together on all sides. As well, both the male as well
as female dovetails extend
only halfway down the block's sides. This results in a bottom ledge in the
female dovetail and prevents
the captive male dovetail from sliding through. Of course there is nothing to
prevent the male dovetail
from sliding back out again. The block faces having dovetails can be secured
in only five of six spatial
directions. When such blocks are used in mufti-layer constructions such as
walls, most of the
half-height male and female dovetails become captive between adjacent blocks.
This reduces the
problem of connections coming apart somewhat. There is a problem however in
using this system to
construct single layer longitudinal objects such as floors or beams.
s A similar half-height dovetail connection method is used on toy blocks of
the brand name
"Kitslink," which is shown in U.S. Patent No. 6,050,044. In this system
however, a stud and cavity
friction-fit type of connection is used to connect blocks on the top and
bottom faces as well. This de-
sign allows construction elements to be engaged to each other on all six
faces, but still the dovetail
sides can be secured in only five of six spatial directions. This is more of a
problem with toys where
more complex structures are constructed as opposed to constructing walls in
the previously mentioned
construction system. One way of keeping the dovetails from sliding apart would
be to use a friction fit,
but this would make the blocks quite hard to put together and especially to
take apart. A real disadvan-
tage of this system when used for toys is that the blocks cannot be pushed
together in the longitudinal
direction of the faces that contain the dovetails. Instead, the block with the
male dovetail must be low-
ered vertically into the female dovetail. As well, when dismantling the
structures, the dovetails must
be withdrawn in the opposite direction of the assembly. The right direction of
disassembly is not clear
when viewing the built structures. When single layer, long beamlike objects
are assembled, the
3
CA 02361993 2003-02-27
half-height dovetails can be subjected to tremendous stress if they are
handled roughly during play. It
is not very difficult to tear apart the dovetails, in which case the blocks
become permanently damaged.
Yet another toy block with brand name "Morphun" is shown in U.S. Patent No.
5,957,744. This
block uses full-length female dovetail or star shaped grooves in the block
sides. To connect the blocks
together, they are placed side-by-side and a star shaped connecter is inserted
into the facing grooves.
This design also does not require studs or other connecting means on the top
and bottom faces because
the star shaped connecters can be taller than the blocks and so can join
blocks both vertically as well as
longitudinally. The star shaped connecter is slightly flexible and is designed
to have a reasonable fric-
tion-fit or a mild compression lock. This makes the structures much more
secure than with the previ-
ous dovetail design, and blocks can be secured on six faces in six spatial
directions. However the
blocks still cannot be pushed together longitudinally on the dovetailed sides
and must be carefully slid
apart from the star shaped connecters to avoid being damaged. The star shaped
connecters are gener-
ally small and so could cause choking in children if they are swallowed.
While both the "Kitslink" and "Morphun" designs result in much more elaborate
constructions
than can be created using the standard "Lego Classic" construction blocks that
locate on only two
faces, both have two inherent problems. Construction using these blocks must
be done in layers, as the
blocks cannot be engaged longitudinally or inserted in the middle of
structures. As well, the blocks are
meant to be disassembled by carefully sliding apart the blocks or connection
elements, and rough dis-
assembly can result in severe damage to the connection elements on the blocks.
The solution to the problem of careful assembly and disassembly has often been
to use a type of
snap-fit connection. In U.S. Patent No. 2,885,822 by "Onanian," a block and
beam construction sys-
tem using split hollow blocks with holes in every face is shown. A round
double male snap-fit connec-
tion element with a pair of outward facing ribs is used to connect blocks
together. Such structures can
be snap-fit together or apart and can be secured on six faces in six spatial
directions. While this design
solves the problems of damage to blocks through rough disassembly, the blocks
can only be inserted
directly towards the face. This design is therefore deficient in that it does
not allow for blocks to slid
into a space. As well, the production of hollow two part blocks is expensive
and the small separate
male connection elements are difficult to remove and could also be a choking
hazard for children.
A popular snap-fit strut type of construction system with brand name "K'nex"
is show in U.S. Pat-
ent No. 5,061,219. In this case, male rods are snap-fit sideways into female
fittings, but now engaging
or separating along the length of the rods is not possible. It is true that
the connections don't need to be
carefully slid apart, but separation by a bending action can result in high
point contact loads that may
4
CA 02361993 2003-02-27
result in some damage to parts. A somewhat similar rod type construction
system is also shown in U.S.
Patent No. 5,704,186 by "Alcalay".
io Another design shown in U.S. Patent No. 5,518,434 by "Ziegler" shows a toy
construction system
using beams having a pair of rounded flexible male forgers which snap-fit into
a female square recess.
Beams are snap-fit together end to end but not side to side. The rounded snap-
fit fingers allow twisting
the connection. This could be an advantage or a disadvantage depending on the
models being built.
a A more versatile snap-fit design with brand name "Lego Znap" is shown in
U.S. Patent No.
5,984,756. In this beam construction system, a pair of flexible female fingers
snap-fit onto a squared
male plug. Connections can be separated sideways or longitudinally with no
damage to the parts.
Various other snap-fit construction elements have been suggested as well. For
example, U.S. Pat-
ent No. 4,126,978 by "Heller" shows an extruded construction channel using a
pair of male ribs which
snap-fit into a female recess with grooves. U.S. Patent No. 3,815,311 by
"Nisula" shows another ex-
truded construction module which contains male ribs which snap-fit into
separate female recesses. A
construction block, shown in U.S. Patent No. 5,970,673 by "Fisher" shows
paired male fingers which
snap-fit into female slots. Another toy, shown in U.S. Patent No. 4,253,268 by
"Mayr" shows a pair of
male curved ribs which slide around an open ended female recess containing a
central post.
i3 Snap-fit connections, especially for toys, are desirable because they can
result in secure side con-
nections, they prevent damage to parts on disassembly, and they are fast to
assemble and disassemble.
The disadvantage of open sided snap-fit systems such as the extruded channels
by "Heller" is that there
is no provision for preventing the joined elements from sliding in the
direction of the grooves. They are
meant for construction systems where a natural ledge such as a floor prevents
movement. Designs
such as "Znap," "Ziegler," and "K'nex," use projections at the ends of the two
open sides of the female
recess. On "Znap" and "Ziegler" designs, only one ledge is used per female
recess side. This still locks
the connection together in six of six possible spatial directions but is much
easier to mold than if paired
ledges were used on each female recess side. The disadvantage of such ledges
on the ends of the fe-
male open sides is that it is difficult to assemble construction elements
because the flexible snap-fit
members must be bent rapidly at the very start of the connection as there is
not enough distance
available generally for a gradual compression.
BACKGROUND-Objects and Advantages
~a The invention is a new modular construction system that incorporates a
novel snap-fit type of con-
nection system that overcomes many of the previously mentioned problems of
construction systems.
CA 02361993 2003-02-27
The objects and advantages of the invention are:
is (a) that construction elements can be easily molded with simple molds which
have a draw in a single
direction or by other inexpensive production methods. No system has been
suggested previously
that has so many advantages and features as the invention and yet can be so
easily produced.
i6 (b) to provide a connection system that is suitable to be used both for
construction blocks as well as a
wide variety of other construction elements. No system has been suggested
previously that can be
built in so many different configurations as the invention.
n (c) to provide a connection system that allows construction elements to be
engaged or separated by
either pushing toward each other or apart, or sliding together or apart. It
appears that only the prior
art "Znap" system can be assembled and disassembled in so many directions, but
this system is not
practical for block construction elements, and is harder to assemble than the
invention.
is (d) to provide a snap-fit connection element that can secure construction
elements in six of six possi-
ble spatial directions. Several prior art systems mentioned can do this,
however they can not be
used in as many configurations or have the same ease of use as the invention.
i9 (e) to provide a construction element that is not required to be made of
multiple pieces. Some prior art
such as "Tatum" use hollow blocks made of two pieces to achieve some of the
advantages claimed
in the invention.
2o (f) to provide a construction system where the connection elements can be
molded integral with the
construction element. Some prior art toy systems such as "Morphun" require
separate connection
elements to be used for engaging construction elements together to achieve the
claimed advan-
tages over prior art, but this could be a choking hazard for children. Most
embodiments of the in-
vention do not require separate connection element pieces to be used.
2i (g) to provide a construction system where the connection elements have
little play when construc-
tion elements are put together yet allows the construction elements to be put
together and taken
apart with little effort. Other prior art such as "Kitslink" with its rigid
dovetail connection system
requires a small amount of clearance between parts for easy assembly. In the
invention, the flexible
snap-fit elements remove this play.
as (h) to provide a connection system where both integral and separate
connection elements can be used.
Very few prior art designs can use both. The invention allows more complex
construction systems
to be made by being able to use both systems.
23
CA 02361993 2003-02-27
(i) to provide a construction system where extremely close manufacturing
tolerances are not re-
quired. Some other snap-fit construction elements with nearly right-angle
connection contact an-
gles require extremely tight manufacturing tolerances. In the invention, less
than right-angle
connection contact angles are preferably used where the connection play can be
removed entirely
even with normal manufacturing tolerances.
za (j) to provide a construction system where two construction elements can be
slid together easily dur-
ing the beginning of the connecting process, which requires less dexterity in
construction. In other
designs such as "K'nex" and "Znap," it is often hard to feel where the
connection elements will go
together. For example, in the "Znap" design, when inserting the male
connection element into the
female connection element vertically, the flexible walls must be bent apart
quickly at the very start
of the connection. In the invention, with this type of sliding together of
connection elements, the
male ribs can be inserted almost half way down the female recess till
encountering some projec-
tions. This makes it much easier to start assembling the two construction
elements before applying
more pressure to ride over these projections.
is (k) to provide a connection system where it is hard to damage the
connection elements during rough
engagement or separation. In other designs such as "Kitslink," the dovetail
connection elements
can be easily damaged. In the invention, the snap-fit connection method
reduces the possible dam-
age substantially by being designed to separate in many different directions.
zs (1) to provide a construction system that can be used with other popular
construction systems. The
various different configurations of the invention can be built to allow mating
with a larger variety
of other construction systems, and allow more adaptors to be built.
z~ (m) to provide a construction system that can be made of inexpensive
materials. Some prior art
snap-fit systems such as "K'nex" and "Znap" are largely made of expensive
Acetal plastic resin.
The invention allows cheaper plastics such as Polypropylene to be used in many
of the
configurations.
zs (n) to make the construction elements look good. Some other prior art such
as "Znap" do not fit to-
gether with the same clean lines due to the design of the snap-fit connection
elements. Most em-
bodiments of the invention result in two interlocking connection elements
where only a simple
rectangular space remains. As well, parts of the connection elements can be
molded flush with the
top and bottom surfaces of the construction element giving a clean, flush
appearance. The full
height connection element features of the invention especially look good when
many block con-
CA 02361993 2003-02-27
struction elements are stacked vertically. The continuous male ribs and female
anti-twist bars on
such walls and columns give them a rich Gothic ribbed appearance.
z9 (o) that construction elements can be engaged on all sides. Some prior art
such as "Lego Technic"
cannot be engaged together on all sides even though this design requires more
expensive molds. In
the invention all sides can be engaged while still being able to be produced
with inexpensive
molds.
30 (p) that construction element can be non-handed. In some prior art such as
"Kitslink" there is either a
male or a female dovetail connection element on sides using dovetail
connection elements. This
requires turning each block to the proper orientation when assembling. In the
preferred embodi-
ment of the invention, a male and a female connection element are paired,
which makes the
connection non-handed.
3i (q) that construction elements can be engaged inverted. In some prior art
such as "Kitslink" or
"Tatum," upright construction elements cannot generally be engaged to inverted
ones. They can be
if in a vertically staggered position only. In the invention, many types of
upright construction ele-
ments can be engaged to inverted ones, though in the preferred embodiment the
blocks must be
staggered horizontally to do so.
32 (r) that construction elements can be engaged staggered vertically. In some
prior art designs such as
"Onanian," each face of the construction elements must match. In the
invention, construction ele-
ments can be securely engaged half way vertically between two other
construction elements.
33 (s) that the connection elements fit between the confines of a stud and
cavity construction system. In
some prior art such as "Kitslink," the dovetail connection elements protrude
too far beyond the
side surfaces of the construction element and so must be placed between a pair
of studs on con-
struction blocks. In the invention, the connection elements are located partly
inside and partly on
the outside of the side surfaces, which allows the connection elements to be
placed directly
between two studs.
so (t) that the connection protrudes minimally outside the construction
element. Again, on prior art such
as "Kitslink," the connection elements protrude substantially beyond the sides
of the construction
elements. In the invention, the connection element is located partly inside
and partly on the outside
of the side surfaces, which reduces the distance the connection elements
project to the outside of
the construction element.
3s (u) to provide a construction system where a construction element will sit
level when placed on its
side. On some prior art designs such as "Kitslink," a single male dovetail
projecting beyond the
CA 02361993 2003-02-27
sides of the construction element does not allow the blocks to stand level by
themselves. In the pre-
ferred embodiment of the invention, paired connection elements are used. Anti-
twist bars, which
are extensions of the female connection element, project outward the same
distance as the male
ribs, and this allows single blocks to be placed level on the sides containing
the snap-fit connection
elements. The connection elements also preferably extend the full height of
each face, which re-
sults in even more stability when they are stood on their sides.
36 (v) allows use of an extra connection locking device. Some prior art such
as "Tatum" and "Kitslink"
use dovetail connection elements that result in a very rigid connection that
doesn't come apart as
readily as a snap-fit connection in general. But these systems are prone to
damage through rough
handling. In the invention, especially when used in larger construction
systems, a wedge spacer
can be inserted in the space between the male ribs, which prevents the
connection element from
separating in all six spatial directions. The ridges and projections holding
together the connection
however are much less in height than the typical dovetail, which still reduces
the chances of dam-
age to the connection over the dovetail connections mentioned when connection
elements are
forced apart.
SUMMARY
3~ A modular construction system featuring an improved snap-fit connection
system that can be in-
corporated into a wide variety of modular type construction elements. In the
invention, all connection
elements are of two categories. First they may be either male or female, where
the male is a rib-like
member than enters a female recess. Secondly the two mating connection
elements can also be of ei-
ther type one or type two. In all embodiments of the invention, the definition
of a type one connection
is that it contains ridges and indentations and is the more resiliently
bendable connection element,
while the definition of a type two connection is that it contains grooves and
projections and is the less
resiliently bendable connection element.
sg In the preferred embodiment of the invention, the type one connection is
male and consists of a
pair of flexible ribs containing ridges and indentations. These ribs snap-fit
into the recess of the type
two connection element which is female, consisting of rigid opposed walls
which contain grooves and
projections. When the connection elements are engaged, the paired ribs fit
tightly between the opposed
walls which prevents movement in the horizontal direction. The ridges on the
ribs locate into the
grooves of the opposed walls which prevents movement in the longitudinal
direction. The indentations
in the ridges locate over the projections in the grooves and this prevent
movement in the vertical direc-
9
CA 02361993 2003-02-27
tion. The female connection element is open on the top, bottom, and front
faces. In the preferred em-
bodiment, this allows the connection element to be either slid together
vertically from the top or
bottom, or longitudinally from the front, or the connection elements can be
rolled together. The
connection elements can also be separated by the reverse procedure.
39 The connection element of the invention is superior to the prior art, as
centrally located indenta-
tions and projections are used to prevent the connection from sliding apart.
Other connection systems
in this general snap-fit class use projections on the open sides of a female
connection element, which
are more difficult to assemble. Other novel aspects of the invention allow for
a much larger variety of
construction elements than the prior art. Many snap-fit type connection
elements are considered to be
hard to mold, but this connection element both can be engaged or separated
easily in a variety of direc-
tions while still being able to be molded inexpensively.
DRAWINGS-Figures
ao The invention will now be described, by way of example only, with reference
to the accompany-
ing drawings, of which:
ai FIGS. 1 to 3 are respectively perspective views of the top, bottom, and a
single side face view of
the preferred embodiment "paired-snap" block type construction element,
showing paired snap-fit
connection elements on faces;
42 FIG. 4 shows a bottom plan view of two construction elements of the
preferred embodiment
joined together;
43 FIG. 5 is a large detailed plan view of a male type one connection element
of the preferred em-
bodiment;
as FIG. 6 is a large detailed plan view of a female type two connection
element of the preferred em-
bodiment;
as FIG. 7 is a large detailed plan view of the preferred embodiment of the
invention showing a male
type one and a female type two connection element engaged;
a6 FIG. 8 is a large scale detailed plan view of four different embodiments of
the male type one con-
nection element with FIG. 8A being similar to the preferred embodiment;
a7 FIG. 9 is a large scale detailed plan view of four different embodiments of
the female type two
connection element with FIG. 9A being similar to the preferred embodiment;
4a FIG.10 is a large scale longitudinal view of three different embodiments
showing the type one in-
dentations with FIG. 10A being similar to the preferred embodiment;
to
CA 02361993 2003-02-27
49 FIG.11 is a large scale longitudinal section view through the plane of the
projections of three dif
ferent embodiments showing the type two projections with FIG. 1 1A being
similar to the preferred
embodiment;
so FIG. 12 shows plan views of three different embodiments of the connection
element with FIG.
12A being closest to the preferred embodiment;
s~ FIGS.13 to 15 are various plan views of two of the construction elements of
FIG.1 shown in vari-
ous stages of connection;
sz FIGS. 16 and 17 are plan views of two of the construction elements of FIG.
1 shown in a
misengaged state;
ss FIG. 18 is a perspective view of two of the construction elements of FIG. 1
in position to be en-
gaged by vertically sliding the snap-fit connection elements together;
sa FIGS. 19 to 22 show top views of some of the different shapes of
construction elements possible
with the paired-snap design of FIG. 1;
ss FIG. 23 is a perspective view of an alternate embodiment beam construction
element with the
paired-snap design of FIG. 1;
s6 FIG. 24 is a perspective view of an alternate embodiment "single-snap"
construction element
showing single-snap connection elements on faces;
s~ FIGS. 25 to 29 show plan views of some of the different shapes of
construction elements possible
with the single-snap connection element of FIG. 24;
ss FIG. 30 is a perspective view of an alternate embodiment "beam"
construction element incorpo-
rating the single-snap connection element of FIG. 24;
s9 FIG. 31 is a perspective view of an alternate embodiment "split-snap"
construction element;
so FIGS. 32 and 33 are perspective and partial sectional views respectively of
an alternate embodi-
ment "beam" construction element incorporating the split-snap design;
FIGS. 34 to 37 show a perspective view and plan views respectively of an
alternate embodiment
"radial-hub" construction element with female type two connection elements;
62 FIG. 38 is a perspective view of an alternate embodiment "strut"
construction element;
63 FIG. 39 is a perspective view of an alternate embodiment "rod" construction
element;
6a FIG. 40 is a perspective view of an alternate embodiment "wire"
construction element;
~s FIGS. 41 to 43 are three perspective views of an alternate embodiment
"panel" construction ele-
ment;
FIG. 44 is a perspective view of a further alternate embodiment panel
construction element;
n
CA 02361993 2003-02-27
s~ FIGS. 45 to 49 are perspective views of an alternate embodiment "plate"
construction element
with various adaptors and elements attached;
sa FIGS. 50 to 52 are perspective views of a related embodiment "wedge spacer"
construction ele-
ment;
69 FIGS. 53 to 56 are perspective views of various "rotator" construction
elements;
~o FIGS. 57 is a perspective view illustrating how construction elements such
as a robot hand can be
fastened to each other;
7i FIG. 58 is a perspective view showing how the preferred embodiment can be
engaged to other
construction elements by inherent features and adaptors;
FIG. 59 is a perspective view of a related embodiment "pry tool" that can be
used to pry apart lay-
ers of construction elements and can also be used to press out wedge spacers;
7s FIG. 60 is a perspective view showing an alternate embodiment "vertical
hole" construction ele-
ment which has a through vertical hole allowing snap-pins and other fasteners
to be used to fasten two
or more construction elements together in the vertical direction;
~a FIGS. 61 and 62 are cross-sectional views on the longitudinal mid-line of
several vertical hole
construction elements engaged together illustrating how rods and snap-pins can
be used to hold blocks
together in the vertical direction;
7s FIG. 63 is a plan view showing an alternate embodiment with a letter on the
top face which can be
linked together to form words;
~s FIG. 64 is a perspective view of an alternate embodiment of the invention
where a slot is used in
the male type one ribs in place of the usual indentation;
FIG. 65 is a perspective view showing an alternate embodiment of a "channel"
construction ele-
ment with paired-snap fasteners and a ridged tubular column for connecting
construction elements
together vertically;
78 FIG. 66 is a perspective view showing a further embodiment of a channel
construction element
with single-snap fasteners;
FIGS. 67 and 68 are plan views showing two alternate construction elements
with male type one
and female type two connection elements;
so FIG. 69 is a plan view comparison between a dovetail connecter and a snap-
fit connecter;
ai FIGS. 70A and 70B are two plan views of generic embodiments of type one and
type two connec-
tion elements showing the scope of the invention.
12
CA 02361993 2003-02-27
DRAWINGS-Reference Letters and Numbers
az X horizontal direction
Y vertical direction
Z longitudinal direction
100 paired-snap construction element
102 male connection element, various embodiments
104 female connection element, various embodiments
106 side surface, paired-snap construction elements
108 top surface
110 stud wall
112 stud cavity
1 I3 cavity stud contact
114 bottom surface
116 tubular wall
118 tubular wall stud contact
120 interior walls, preferred embodiment
122 top radius, all construction elements
123 bottom radius, all construction elements
124 inner wall stud contact
126 rib, male type one connection element
127 rib end surface, male type one connection element
128 ridge, type one connection element
129 ridge outer surface, type one connection element
130 indentation, type one connection element
132 ridge ramp, type one connection element
134 ridge ramp radius, type one connection element
136 rib outside surface, male connection element
138 rib cavity, male connection element
140 ridge outer radius, male connection element
141 rib inner radius, male connection element
142 depression, various embodiments
143 depression end surface, various embodiments
13
CA 02361993 2003-02-27
144 depression outer surface, various embodiments
146 indentation upper ramp, type one connection element
148 indentation vertical flat, type one connection element
150 indentation lower ramp
151 opposed walls, female connection element
152 recess, female type two, various embodiments
154 groove, type two connection element
155 groove outer surface, type two connection element
156 endwall, female connection element
157 groove ramp, type two connection element
158 groove ramp radius, type two connection element
160 opposed wall surface, female connection element
161 anti-twist bar angle
162 anti-twist bar, female connection element
163 anti-twist bar front surface
164. recess inner radius
166 anti-twist bar outer surface
168 projection, type two connection element
170 projection upper ramp, type two connection element
172 projection vertical flat, type two connection element
174 projection lower ramp, type two connection element
176 cavity inside radius, preferred embodiment
178 tubular cavity, paired-snap construction elements
179 tubular cavity contact, paired-snap construction elements
180 rib inner surface
181 rib angle
182 connection radius, common
184 45 degree ridge ramp angle
186 90 degree ridge ramp angle
188 135 degree ridge ramp angle
190 bulbous ridge ramp
192 45 degree groove ramp angle
14
CA 02361993 2003-02-27
194 90 degree groove ramp angle
196 135 degree groove ramp angle
198 bulbous groove ramp
200 45 degree indentation upper ramp
202 45 degree indentation lower ramp
204 90 degree indentation upper ramp
206 45 degree indentation lower ramp
208 135 degree indentation upper ramp
210 45 degree indentation lower ramp
212 45 degree projection upper ramp
214 45 degree projection lower ramp
216 90 degree projection upper ramp
218 45 degree projection lower ramp
220 135 degree projection upper ramp
222 45 degree projection lower ramp
224 square ribs, connector lead-in
225 square rib, connector lead-in
226 divergent opposed walls, connector lead-in
227 divergent recess, connection lead-in
228 angled ribs, connection lead-in
229 tapered rib, connection lead-in
230 square recess edge, connection lead-in
231 square recess, connection lead-in
232 radiused ribs, connection lead-in
233 radiused rib, connection lead-in
234 recess radius, connection lead-in
235 parallel opposed walls, connection lead-in
236 parallel recess, connection lead-in
237 longitudinal engagement
238 rocking point
240 vertical engagement
242 rectangular construction element, paired-snap
CA 02361993 2003-02-27
244 equilateral triangle construction element, paired-snap
246 pie shaped construction element, paired-snap
248 right isosceles triangle construction element, paired-snap
249 beam construction element, paired-snap
250 single-snap construction element, square
251 side surface, single-snap
252 rectangular construction element, single-snap
254 equilateral triangle construction element, single-snap
256 pie shaped construction element, single-snap
258 right isosceles triangle construction element, single-snap
260 six sided polygon construction element, single-snap
262 beam construction element, single-snap
264 female split-snap connection element, type two
266 side A rib, split-snap
268 side B rib, split-snap
270 split-snap construction element, square block
272 short split-snap construction element
274 long split-snap construction element
275 filler construction element, split-snap
276 side surface, female split-snap
278 beam hole
280 beam construction element, split-snap
282 180 degree radial-hub construction element
284 90 degree radial-hub construction element
286 straight radial-hub construction element
288 hole, radial-hub
290 radial-hub construction element, female type two, 360 degree
292 side surface, female radial-hub
294 strut body, radial-hub
296 male split-snap connection element, type one
298 side surface, male radial-hub
300 strut construction element, radial-hub
16
CA 02361993 2003-02-27
302 rod construction element, radial-hub
304 rod body, radial-hub
306 wire construction element, radial-hub
308 wire body, radial-hub
310 rib, split-snap male type one
312 panel one construction element
314 sheet, panel one
316 panel three construction element
318 divider, panel three
320 panel two construction element
322 panel four construction element
324 panel tab, panel four construction element, female type two
326 gap, panel four construction element, female type two
328 groove, panel four construction element, female type two
330 stud plate construction element
332 stud, stud plate construction element
334 sidepin plate construction element
336 side pin, sidepin plate construction element
338 plate, tab plate construction element
340 tab plate construction element
342 holes, tab plate construction element
344 plate, split plate construction element
346 holes, split plate construction element
348 floor panel, split plate construction element
350 split plate construction element
352 window construction element
354 single-snap plate, window construction element
356 window, window construction element
358 wedge spacer radius
360 wedge spacer construction element
362 protrusion, wedge spacer construction element
364 rib notch, wedge spacer construction element
m
CA 02361993 2003-02-27
366 long wedge spacer construction element
368 side C ribs, split-snap rotator
370 split-snap rotator
372 side D ribs, split-snap rotator
374 XZ rotator
376 side E, XZ rotator
378 side F, XZ rotator
380 Y rotator
382 side G, Y rotator
384 side H, Y rotator
386 side J, pivot rotator
388 side K, pivot rotator
390 pivot rotator
392 pin, pivot rotator
394 robot hand construction element
396 "Lego Duplo"
398 "Lego Classic"
400 stud adaptor construction element
402 "Morphun"
404 "Kitslink"
406 wedge spacer punch, pry tool
408 tip radius, pry tool
410 pry tool
412 vertical hole, vertical hole construction element
414 countersink, vertical hole construction element
416 snap pin
418 threaded rod
420 vertical hole construction element
422 letter
424 rib with slots, male type one
426 rib, rib with slots
427 slot, rib with slot
18
CA 02361993 2003-02-27
428 upper slot ramp, rib with slots
429 lower slot ramp, rib with slots
430 paired-snap channel construction element
432 channel, paired-snap channel construction element
434 tubular column, paired-snap channel construction element
435 ridge, tubular column
436 channel, single-snap channel construction element
438 ribs, single-snap channel construction element
440 single-snap channel construction element
442 construction element, no anti-twist bar and no depression
443 construction element, no anti-twist bar but with depression
444 connection element, female type two, no anti-twist bar
446 snap-fit connection element
448 dovetail connection element
450 generic male type one connection element, flexible ribs
452 generic female type two connection element, rigid walls
454 generic male type two connection element, rigid ribs
456 generic female type one connection element, flexible walls
458 ribs, male type one, flexible ribs
460 rib cavity
462 ridge, mate type one
464 indentation, male type one
466 generic connection radius
468 recess, female type two
470 opposed walls, female type two, rigid walls
472 groove, female type two
474 projection, female type two
476 rib(s), male type two, rigid
478 groove, male type two
480 projection, male type two
482 recess, female type one
484 opposed walls, female type one, flexible walls
19
CA 02361993 2003-02-27
486 ridge, female type one
4$8 indentation, female type one
490 rib cavity, rigid rib
DESCRIPTION-FIG. 1-23-Paired-Snap
s3 Many construction elements can be designed around the basic snap-fit
connection system of the
invention. Only some of the embodiments of the snap-fit connection element and
the variously shaped
construction elements that are possible are discussed in the sections that
follow. The preferred em-
bodiment of the snap-fit construction system is shown in this first section
and will most fully describe
the details of the snap-fit connection element and also its operation.
as As shown in FIG.1 and 2, the preferred embodiment of the invention is a
paired-snap construction
element 100 in the form of a block, which has a generally parallelepiped
hollow configuration allow-
ing for easy molding. The paired-snap construction element 100 has connection
elements on a top sur-
face 108, a bottom surface 114, and a plurality of side surfaces 106.
ss The directional orientation of all connection elements relate to a head on
view of the single side
surface 106 of the paired-snap construction element 100 as shown in FIG. 3.
Each pair of positive and
negative spatial directions of the connection securing is shown in the spatial
diagram. The directional
names are defined as X for a horizontal direction, Y for a vertical direction,
and Z for a longitudinal di-
rection. It should be appreciated however that all the construction elements
can be and are used in any
orientation.
a6 Stud connection elements are used for connecting the top surfaces 108 and
the bottom surfaces
114 together. A raised stud wall 110 with a stud cavity 112 are located on the
top surface 108. The stud
cavity 112 has four stud cavity contacts 113, which are symmetrically
positioned flat parallel surfaces
on its sidewall to be able to connect frictionally to small studs or tubes of
other construction elements.
The remaining areas of the stud cavity 112 can be tapered to allow for easier
ejection from the mold.
s7 A tubular wall 116 depending from the walls of the top surface 108, passes
through the
paired-snap construction element 100 to approximately the plane of the bottom
surface 114. A tubular
cavity 178 is located in the center of the tubular wall 116 which has four
tubular cavity contacts 179,
which are symmetrically positioned flat parallel surfaces on its sidewall to
be able to connect
frictionally to rods and pins of other construction elements. The remaining
areas of the tubular cavity
178 can also be tapered to allow for easier ejection from the mold.
as
CA 02361993 2003-02-27
A plurality of interior walls 120 are located on the interior of the paired-
snap construction element
100 and provide additional strength and reinforcement. The interior walls 120
depend from the walls
of the side surfaces 106, the walls of the top surface 108, and the tubular
wall 116, and pass through the
interior of the paired-snap construction element 100 approximately three
quarters of the distance from
the walls of the top surface 108 to the plane of the bottom surface 114. The
length of the interior walls
120 in the vertical direction Y may however be varied from zero to the full
distance between the walls
of the top surface 108 and the bottom surface 114. The tubular wall 116
however ideally projects
nearly to the bottom surface 114 because it provides a tubular wall stud
contact 118, which is a first
stud contact, on its exterior surface. An inner wall stud contact 124 is
present for providing the remain-
ing two of three stud contact surfaces for fricdonally connecting to the stud
walls 110 of a connecting
paired-snap construction element 100. The inner wall stud contacts 124 ideally
are only slightly longer
vertically than the mating stud walls 110 are in length, allowing the
remaining wall of the side surface
106 in the direction towards the top surface 108 to have a greater wall
thickness. A cavity inside radius
176 in the interior of the paired-snap construction element 100 between the
walls of the top surface
108 and the walls of the side surfaces 106 and the interior walls 120, as well
as between the interior
walls 120 and the walls of the side surface 106, helps to increase the impact
resistance of the
construction element.
a9 In the invention, all snap-fit connection elements are of twa categories.
First they may be either
male or female, where the male is a rib-like member than enters a female
recess. Secondly the two mat-
ing connection elements can also be of either type one or type two. In all
embodiments of the inven-
tion, the definition of a type one connection is that it contains ridges and
indentations and is the more
resiliently bendable connection element, while the definition of a type two
connection is that it con-
tains grooves and projections and is the less resiliently bendable connection
element. In this preferred
embodiment as well as most alternate embodiments, the type one connection
element is male and the
type two connection element is female.
~o A male type one connection element 102, as shown in FIG. 1 to 7, comprises
of a pair of ribs 126
extending outward in the longitudinal direction Z from a depressed position
below the side surface 106
of the paired-snap construction element 100. By extending from a depressed
position, the ribs 126 can
generally be made longer in the longitudinal direction Z. This allows the ribs
126 to be more flexible
for a certain rib thickness in the horizontal direction X and also results in
a wide range of advantages in
this application. A depression 142 is located adjacent to each outermost
surface of the ribs 126. This
depression 142 is as deep as the distance the ribs I26 extend past the plane
of the side surface 106. As
21
CA 02361993 2003-02-27
shown in FIG. 5, the depression 142 contains a depression end surface 143,
which is used as a stop, and
a depression outer surface 144, which is angled outward.
9i A ridge 128 protrudes outward in the horizontal direction X from each
outermost side of the ribs
126. Each ridge 128 contains a ridge ramp 132 which is angled at 45 degrees to
the horizontal direction
X in the XZ plane.
92 As shown in FIG. 3, an indentation 130 is located on each of the ridges
128. The indentation 130
has an indentation vertical flat 148, which extends in the vertical direction
Y, an indentation upper
ramp 146, and an indentation lower ramp 150. Both the indentation upper ramp
146 and the indenta-
tion lower ramp 150 slope away from the indentation vertical flat 148 at an
angle of 45 degrees to the
vertical direction Y in the XY plane. The indentations 130 on each of the ribs
126 are both of the same
height in the vertical direction Y and located in the vertical center of the
ridges 128.
93 A female type two connection element 104, as shown in FIGS. 1 to 7,
comprises of a pair of op-
posed walls 151 extending inwards from the side surface 106 in the
longitudinal direction Z and end-
ing at an endwalI 156. The void between the opposed walls 151, the endwall
156, and extending
outwards is a recess 152, which is open at its top, bottom and an outward
face.
~a A groove 154 is located in each of the opposed walls 151 nearest the
endwall 156 and runs in the
vertical direction Y. This groove 154 contains a groove ramp 157 as shown in
FIG. 6. The groove
ramps 157 are also angled at 45 degrees to the horizontal direction X in the
XZ plane, such that when
the male connection element 102 and female connection element 104 are engaged,
counterpart angled
surfaces of the ridge ramps 132 and the groove ramps 157 fit flush against
each other.
9s A projection 168 is located in each groove 154 as is illustrated in FIGS.
3. The projections 168
have a projection vertical flat 172, which extends in the vertical direction Y
, a projection upper ramp
170, and a projection lower ramp 174, which both slope away from the
projection vertical flat 172 at an
angle of 45 degrees to the vertical direction Y in the XY plane. The
projections 168 are located in the
vertical center of each groove 154 to match up with the positioning of the
indentations 130 on the
ridges 128. The projections 168 extend out from the grooves 154 in such a way
as to mate perfectly
with the shape of the indentations 130 in the ridges 128 when engaged.
As shown in FIG. 4 to 7, the opposed walls 151 extend past the plane of the
side surface 106 to be-
come a pair of anti-twist bars 162 which provide additional torsional
stability to engaged construction
elements as well as preventing movement in the horizontal direction X. They
also fill up the space of
the depressions 142 and this results in a clean look. The anti-twist bars 162
and the ribs 126 extend an
equal distance past the plane of the side surface 106 of the paired-snap
construction element 100,
22
CA 02361993 2003-02-27
which allows the construction element to sit level when placed on its side.
The anti-twist bars 162 are
tapered. The anti-twist bar 162 contains an anti-twist bar outer surface 166
and an opposed wall sur-
face 160, which are angled inward with an anti-twist bar angle 161 such that
the pair of anti-twist bars
162 become narrower as they project in the longitudinal direction Z from the
paired-snap construction
element 100. Having the anti-twist bar angle 161 at about 9 degrees is ideal.
An anti-twist bar front sur-
face 163 is used as a stop. The depressions 142 become narrower as they
penetrate into the paired-snap
construction element 100. The tapered anti-twist bars 162 fit into the
depressions 142 with a small
amount of side clearance, which allows for easier engagement and separation.
When the male connection element 102 is engaged within the female connection
element 104, the
ribs 126 do not snap back to their unengaged state. They continue to press
against the opposed walls
151. They are designed to have what can be called a preload. Ideally a rib
cavity 138 should be parallel
after engagement. In this case a pair of rib inner surfaces 180 and the rib
cavity 138 will need to be di-
vergent towards the free ends of the ribs 126 in the unengaged state. As shown
in FIG. 5 to 7, a rib an-
gle 181 of about 2.5 degrees is ideal when the male connection element 102 is
not engaged. The
paired-snap construction element 100 has a preload force of approximately 25
°lo of the maximum flex-
ing force experienced during engagement. This amount of preload works best for
toys.
9a The opposed wall surfaces 160 of the female connection element 104 are
divergent is they extend
outward in the longitudinal direction Z. A longitudinal engagement 237 of two
construction elements,
as shown in FIG. 13 is easier when the ribs 126 can partly engage into the
recess 152 in their non bent
state. The slight angle of the opposed wall surfaces 160 gradually bends the
ribs 126 together as they
are inserted into the recess 152.
As shown in FIG. 5 to 7, the ribs 126 have a rib outside surface 136, which is
angled to roughly
match that of the opposed wall surfaces 160. A close fit results in greater
rigidity of the connection ele-
ments in both torsion and the horizontal direction X. However, to avoid hang-
ups of the male connec-
tion element 102 and the female connection element 104 due to parting line
flashing and unevenness of
the parts from the molding operation, small clearances exist between many of
the mating surfaces. So
it is ideal to have a small clearance between the rib outside surface 136 and
opposed wall surface 160,
as the ribs 126 should rather contact at the groove ramp 157 and the ridge
ramp 132. Ideally there is
also a very small amount of clearance between a ridge ramp radius 134 and a
groove ramp radius 158.
There should also be clearance between a groove outer surface 155 and a ridge
outer surface 129, as
well as between a rib end surface 127 and the endwall 156.
ioo
23
CA 02361993 2003-02-27
Various radiuses on the construction element exist for both functional and
esthetic reasons. A top
radius 122 along the edge of the top surface 108, as well as a corresponding
bottom radius 123 at the
edge of the bottom surface 114 of the paired-snap construction element 100,
extends all the way along
the side surfaces 106 as well as around the male connection element 102 and
the female connection el-
ement 104. The rounded edges are quite pleasing to the eye, but also are
designed to prevent harm to
those handling the construction element. The connection and construction
element wall thicknesses
are designed to be of a large enough dimension that they can accept a uniform
and continuous radius
around the entire edge, which results in a pleasant uniform look. Another
purpose of the top radius 122
and the bottom radius 123 is to provide a rounded edge for a vertical
engagement 240 of two
paired-snap construction elements 100 as shown in FIG. 18. The rounded edges
of the female connec-
tion element 104 enlarge the opening, and the rounded edges of the male
connection element 102 thin
the edges, allowing the connection elements to be aligned easier and act like
small ramps to gradually
compress the ribs 126 together when they are being inserted into the female
recess 152. Likewise, in
the longitudinal engagement 237, the connection elements are aligned easier
because the front edge of
the rib 126 contains a ridge outer radius 140 and the anti-twist bar 162
contains a recess inner radius
164.
~o~ The width in the horizontal direction X of the rib cavity 138, the
depression 142, and the anti-twist
bar 162 are dimensioned so that they can interfit without damaging the
connection elements in case the
paired-snap construction elements 100 are misassembled. In FIG. 16, the anti-
twist bar 162 is shown
inside the rib cavity 138. Ideally the rib cavity 138 is sized so that the
ribs 126 would not need to spread
outward much at all, reducing the stress on the ribs 126. In FIG. 17, two of
the ribs 126 are shown in-
side the depression 142 and the rib cavity 138. Ideally here as well, the rib
cavity 138 and the depres-
sion 142 should be sized so that the ribs 126 fit easily into them and that
the ribs 126 would not need to
spread outward much at all, again reducing stress on the ribs 126. If properly
sized for a slight com-
pression fit, the insertion shown in FIG. 17 can be used as a type of weak
connection. A rib inner radius
141 and the ridge outer radius 140 match a connection radius 182, found at the
base of the ribs 126 and
outside of the anti-twist bar 162, and this also reduces the stress on the
connection elements when they
are misassembled.
io2 The ribs 126, the depression 142, the grooves 154, and the anti-twist bars
162, travel the full
height of the paired-snap construction element 100 from the bottom surface 114
to the top surface 108.
This results in the strongest connection and is the most pleasing to the eye
because the connection ele-
24
CA 02361993 2003-02-27
menu are flush with the top surface 108 and the bottom surface 1 I4 of the
construction element when
engaged.
X03 Through the use of all the connecting elements just described, the paired-
snap construction ele-
ment 100 may be joined on all faces, and all faces can be secured in six of
six possible spatial direc-
tions. A combination of studs and snap-fit connection elements are used
because this results in the
paired-snap construction element 100 being easy to mold, as all the features
are generally collinear.
The stud walls 110 and the stud cavities 112 provide compatibility with other
construction systems.
For example when the paired-snap construction element 100 has the same basic
block and stud dimen-
sions as "Lego Duplo" 396, the outer surface of the stud walls 110 can connect
to the "Lego Duplo"
396 blocks and the stud cavities 1 I2 can be used to connect to the tubes of
the smaller "Lego Classic"
398 construction elements. Various prior art construction elements are
illustrated in FIG. 58.
X04 The stud connection system connects together through friction between the
contact faces. The
stud dimensions are sized to fit with interference between the confines of the
mating stud wall 110, the
inner wall stud contacts 124, and the tubular wall stud contact 118. One of
the problems with molding
a hollow construction element is that it is difficult to keep the walls
parallel during molding. This can
greatly affect the position of the inner wall stud contacts 124 and results in
either the stud connection
being loose or too tight. The interior walls 120 greatly increase the
dimensional stability of the side-
walk. Polypropylene is also a good material for the construction elements
because it is more stable
dimensionally in this regard during molding than other materials such as
Acetal or Styrene. Using the
tubular wall 116 is quite desirable and is also used on many prior art
construction systems. It allows
construction elements to be joined with as little as one stud in contact.
ios Engagement on the side surfaces 106 of the paired-snap construction
element 100 is achieved in
six of six possible spatial directions by way of the snap-fit connection
elements in the following way
shown in FIGS. 3 to 7. The pair of male ribs 126 secures the two construction
elements in the two hori-
zontal directions X+ and X- by fitting into the female recess 152. The actual
surfaces that provide re-
sistance in this direction are the ridge ramp 132 and the groove ramp 157. The
pair of ribs 126 are
pushing apart in opposite directions due to the preload on the ribs. As well
the ribs 126 are being con-
strained from moving apart too far by other contact surfaces that act as stops
in the longitudinal direc-
tion Z. The connection is secured in the two longitudinal directions Z+ and Z-
by the ridge ramp 132
reacting against the groove ramp 157 in one direction and the anti-twist bar
front surface 163 reacting
against the depression end surface 143. Finally, to secure the connection in
the two vertical directions
Y+ and Y-, the pair of indentations 130 fit into the pair of projections 168.
Because the indentations
CA 02361993 2003-02-27
130 and the projections 168 have a pair of opposite angled surfaces, this
secures the connection in both
of these directions. The indentations 130 and ridges 128 are on the same rib
126, so each pair of ribs
holds the connection elements together in six spatial directions. The flexural
resistance of the ribs 126
is what provides resistance to the connection coming apart.
ios Each side surface 106 of the paired-snap construction element 100 has both
the male connection
element 102 and the female connection element 104 positioned so that two
construction elements may
be engaged as shown in FIGS. 13,14,15,18. The advantage of using paired-snap
connection elements
is that the construction element does not have to be carefully oriented before
insertion, as each side can
be engaged to any other side. By angling the opposed wall surfaces 160, having
tapered anti-twist bars
162, plus a small amount of clearance between the anti-twist bars 162 and the
depressions 142, en-
gagement and separation of adjacent construction elements is made easier. The
two construction ele-
ments may be engaged or separated in several ways:
ion (a) By longitudinal engagement 237 as illustrated in FIG. 13, or
separation in the reverse direction.
Los (b) By vertical engagement 240 as illustrated in FIG.18, where the male
connection elements 102 ei-
ther slide down or up in relation to the female connection element 104, or
separation in the reverse
direction.
m (c) By rolling the two connection elements together in the XZ plane as shown
in FIG. 15, where a
rocking point 238 acts as a fulcrum during engagement or separation. A first
and then a second
connection element is pushed together, or separation in the reverse direction.
> >o (d) By rolling the construction elements together in the YZ plane , where
first the top or bottom of the
construction element is pushed together in the longitudinal direction Z and
then the construction
elements are rolled together, or separation in the reverse direction.
i i i (e) Through a combination of vertical, horizontal, and longitudinal
motion, or separation in the re-
verse direction.
i ~2 The combination of the indentations 130 and the projections 168 provides
substantial resistance to
movement in the vertical direction Y. It is therefore possible to construct
significant spans such as
bridges or beams in the longitudinal direction Z. In addition, construction
elements can be engaged
anywhere along the side surfaces 106 of walled structures without removing any
construction ele-
ments above as in many prior art systems. Construction elements can be engaged
onto other construc-
tion elements above or below a desired position and then slid up or down in
the vertical direction Y to
26
CA 02361993 2003-02-27
connect with the stud connection system of the desired construction element.
It is also possible to join
construction elements in a step-like fashion, or between vertical construction
elements, with the bot-
tom of the ribs 126 resting on the projections 168. Paired-snap construction
elements 100 can also be
joined upside down if the joint is staggered in the horizontal direction X.
~ is Having the indentations 130 and the projections 168 near the vertical
center of the ribs 126 allows
the ribs 126 to be inserted almost half way down the recess 152 before the
additional force due to the
ribs 126 having to bend over the projections 168 is encountered. By this point
the two paired-snap con-
struction elements 100 are well located and parallel at which time a less
careful push is required. This
makes it easier to assemble than some prior art such as "Lego Znap." The
centrally located indentation
130 requires a more ingenious mold design than the prior art, but it makes the
connection system easy
to use.
as In some prior art construction systems, the snap-fit connection elements
have a fair amount of
play. The snap-fit connection elements in the invention can be designed to
have no play or very little
play, which has obvious advantages when many construction elements are engaged
together. A tight
connection with the invention can be achieved because the connection has
movable and self tighten-
ing elements in each of the three spatial directions due to the angles that
can be used. In the paired-snap
construction element 100, a tight connection in both the horizontal directions
X+ and X-, as well as the
longitudinal directions Z+ and Z- can be achieved because of the 45 degree
angular contact of the
ridge ramp 132 and the groove ramp 157. As well, the male ribs 126 have a
preload, so they are push-
ing outward in the female recess 152. The ridge ramps 132 slide against the
groove ramps 157 till they
stop, in which case the connection is tight in both these directions when the
appropriate clearances
elsewhere are maintained. A tight connection can also be attained due to the
ribs 126 being slightly
flexible along their length in the vertical direction Y. When considering
tolerances, it would be hard to
get the ridge ramps 132, the groove ramps 157, as well as all the surfaces of
the indentation 130, and
the projections 168 to seat with zero clearance. The connection elements
however can be designed so
that the indentations 130 seat with the projections 168 first. In this case,
the ribs 126 being slightly
flexible along their height in the vertical direction Y, will be restrained
from flexing outward from
each other at the vertical center but will be able to flex outward from each
other more at the top surface
108 and the bottom surface 114. This allows the ribs 126 to still contact the
ridge ramps 132 and the
groove ramps 157 at the top surface 108 and the bottom surface 114 of the
connection in such a way
that there will be no play in the connection. Play in the vertical direction Y
can be avoided if the
projections 168 do not completely bottom out in the indentations 130.
27
CA 02361993 2003-02-27
> >s As shown in FIG. 7, two paired-snap construction elements 100 also have
some space between the
opposing side surfaces 106 when placed together. There are only a few selected
surfaces on the mating
connection elements that are actually in contact with each other. This means
that the outside dimen-
sions do not have to be as accurate or flat, which is good, as the side
surfaces 106 can be slightly curved
after molding.
i ~s The male connection element 102 having the depression 142 next to the
ribs 126, generally allows
the ribs 126 to be longer in the longitudinal direction Z than if they only
extended from the side surface
106. An alternate embodiment without this depression 142 is shown in FIG. 67.
There are several ad-
vantages in using such longer ribs 126 especially when stud type connecting
systems are used on the
top and bottom surfaces on smaller toy construction sets. FIG. 4 shows that
when two paired-snap con-
struction elements 100 are engaged, there is little room between two facing
stud walls 110. If the rib
126 would extend directly from the side surface 106, the rib 126 would need to
be roughly one-half as
long. The male connection element 102, already has a ridge length that is
nearly 30°l0 of the total rib
length in the longitudinal direction Z. If either the ridge 128 is shorter in
the longitudinal direction Z,
or lower in the horizontal direction X to reduce the need for bending, or the
ribs 126 are thinner in the
horizontal direction X to allow for easier bending, problems are experienced.
Already the ribs 126 are
nearly as thin as the thinnest part on the construction element and making
them thinner would result in
either molding problems or sharper corners. The ridge 128 being lower in the
horizontal direction X is
not very practical because of tolerances, and the ridge being shorter in the
longitudinal direction Z
would wear the groove 154. FIG. 4 shows that the balanced connection element
design of the
paired-snap construction element 100 results in efficient use of the space
between the two opposite
facing stud walls 110.
~ a Having all the connection elements molded as part of the construction
element has advantages es-
pecially for toy construction sets. This way there are no separate connection
pieces that can choke a
child if swallowed. Less total pieces are required when packaging.
us While the paired-snap construction element 100 is in the shape of a square,
many other shapes
may be made in order to develop a diverse set of construction elements for a
multitude of construction
sets. For example, FIGS. 19 to 23 illustrate some of the variety of shapes and
configurations of con-
struction elements possible using paired-snap connection elements of the
invention. A rectangular
construction element 242 is not as necessary when using snap-fit connection
elements on the side faces
as with prior art such as "Lego Classic" 398. An equilateral triangle
construction element 244 is a use-
ful construction element especially with paired-snap connection elements
because it has connection
28
CA 02361993 2003-02-27
elements on all sides and can be put together in a solid matrix just like
square construction elements. A
pie shaped construction element 246 is useful for constructing circular
shapes. A right isosceles trian-
gle construction element 248 can be used for mitered comers. A beam
construction element 249 has no
snap-fit connection elements on its sides and some embodiments may not use
stud type connections on
the top surface.
a9 It is also contemplated that different construction elements will have
different numbers and pat
terns of male and female connection elements per side as discussed in the
following section.
DESCRIPTION FIG.24-30-Single-Snap
~2o An alternate embodiment of the invention is a single-snap construction
element 250 as shown in
FIG. 24. The male connection element 102 and female connection element 104
used are identical to
those of the paired-snap construction element 100, only here a minimum of one
snap-fit connection el-
ement is used on each side. Having only one connection element per side has
some disadvantages over
using paired snap-fit connection elements, but there can be several reasons
for doing so. For example,
the single-snap construction element 250 shown can be a small construction
element to be used to-
gether with the larger paired-snap construction element 100. If the length of
each side of the sin-
gle-snap construction element 250 is one-half that of the larger paired-snap
construction element 100,
it would be compatible. If the same studs are used, this makes the design even
more complimentary
than prior art designs such as "Lego Duplo" 396 and "Lego Classic" 398 which
use different sized
studs for a reason. Because "Lego Duplo" 396 and "Lego Classic" 398 do not
have side connection ele-
ments, the construction elements must be staggered overtop of each other to
build sideways. A mini-
mum of 2 stud rows is then a minimum. Construction elements with connection
elements on the sides
do not have this limitation and can more practically be made using single rows
of studs. The sin-
gle-snap construction element 250 could be also made one-half the height of
paired-snap construction
element 100 for example, but this might result in an imperfect match with the
indentations 130 and the
projections 168 in some situations. Using the same indentation 130 and
projection 168 dimensions for
both the paired-snap construction element 100 and single-snap construction
element 250 would at
least allow them to be properly engaged at mid height.
~Zi Just as with the previous paired-snap design, many other shapes may be
made in order to develop
a diverse set of construction elements. FIGS. 25 to 30 illustrate a variety of
shapes and configurations
of construction elements using single-snap connection elements of the
invention. A rectangular con-
struction element 252 is now a more practical construction element than the
square one. An equilateral
29
CA 02361993 2003-02-27
triangle construction element 254 is now not as useful a construction element
because it cannot be
made into a solid matrix. A pie shaped construction element 256 is still
useful for constructing circular
shapes. A right isosceles triangle construction element 258 can still be used
for mitered corners. A
six-sided polygon construction element 260 could be used for a type of radial
construction system. A
beam construction element 262 with single-snap connection elements on each end
could be made quite
narrow.
m In the paired-snap construction element 100, the contact points between
engaged construction e1-
ements Were preferably only in the connection area. This would result in an
undesirable amount of
movement with the single-snap construction element 250 and so it would be
better to have very little
clearance between a side surface 251 when two construction elements are
engaged. Because the side
surface 251 is much less in area than that of the paired-snap construction
element 100, this is not as big
a disadvantage. It is also contemplated that there would be various other
combinations of this design.
DESCRLPTION FIG.31-Split-Snap
its Another alternate embodiment of the invention is a split-snap construction
element 270, as illus-
trated in FIG. 31, which does not contain male connection elements. Only a
female type two split-snap
connection element 264 is used, which is identical to the female connection
element 104 except that it
doesn't have anti-twist bars 162 and is fully sunken below the side surface
276. The female split-snap
connection element 264 contains the same grooves 154 and projections 168 of
the paired-snap
construction element 100.
m The male type one connection element is now part of a short split-snap
construction element 272
or a long split-snap construction element 274, primarily consisting of a pair
of side A ribs 266 and an-
other pair of side B ribs 268 which are opposed to the first pair and
preferably all of equal length. These
are basically double-sided versions of the male connection element 102 of the
paired-snap construc-
tion element 100 without the depressions 142 and contains the same ridges 128
and the indentations
130. When two split-snap construction elements 270 are engaged together they
would ideally touch to-
gether on a side surfaces 276.
~is One of the advantages of the paired-snap construction element 100 and the
single-snap construc-
tion element 250, shown in FIGS. 1 and 24 respectively, is that the connection
elements are captive on
a generally larger construction element. When used for toys with construction
elements of sufficient
size, this prevents children from swallowing and choking on tiny construction
elements. Perhaps this
would make the split-snap construction element 270 less desirable for small
toys, but it would be quite
CA 02361993 2003-02-27
ideal for larger construction systems. The split-snap construction element 270
has the advantage that
there are no connection elements protruding unnecessarily from the sides of
constructions. A fiber
construction element 275 can be inserted to make the split-snap construction
element 270 flush on the
sides. The split-snap construction element 270 does not really require stud
walls 110 because the long
split-snap construction element 274 can be used to fasten split-snap
construction elements 270 above
and below as well as on sides. The long split-snap construction element 274
ideally would contain
multiple indentations 130 along its length to match those of multiple
vertically stacked split-snap con-
struction elements 270. Because the long split-snap construction element 274
contains flexible mem-
bers, it could still be produced with an inexpensive molding process similar
to what would be used to
produce the paired-snap construction element 100.
izs While the split-snap construction element 270 shown is in the shape of a
block, the same details
can be used to produce new construction elements such as beam, radial-hub,
strut, flexible rod, wire,
and panel construction elements.
DESCRIPTION-FIG. 32-33-B earns
iz~ Another alternate embodiment of the invention is a beam construction
element 280, as is shown in
FIG. 32, which has no snap-fit or stud type connection elements on one pair of
sides, but rather uses a
beam hole 278. Such beam holes 278 have been used for example on the "Lego
Technic" series for
some time and can be used to connect a variety of construction elements
together or the beam holes
278 can be used as bearings for shafts. FIG. 33 shows details of where the
beam holes 278 would ide-
ally be located, which would be underneath each stud wall 110.
izs On each end of the beam construction element 280, female split-snap
connection elements 264
would be used. The beams would be fastened together with the short split-snap
construction element
272. The ends of the beam construction element 280 would touch each other on
the side surfaces 276.
Tests have shown that such a connection, even with the narrow bearing area of
the side surface 276,
can result in a very tight connection and fairly long overhanging spans are
possible.
DESCRIPTION-FIG. 34-37-Radial-Hubs
az9 Another alternate embodiment of the invention is a radial-hub construction
element 290 shown in
FIG. 34 which can be used together with other construction elements such as
the strut, rod, and wire
construction elements shown later. Actually the radial-hub construction
element 290 is like the
31
CA 02361993 2003-02-27
split-snap construction element 270 but with a more open molded structure and
uses the same female
split-snap connection element 264. The radial-hub construction element 290 has
eight female
split-snap connection elements 264 arranged at 45 degree increments. The
radial-hub construction ele-
ment 290 also contains a hole 288 at the center point of the radial
arrangement. With the right dimen-
sions, the radial-hub construction element 290 could be made to connect
directly to the split-snap
construction element 270 and beam construction element 280. Alternately the
radial-hub construction
element 290 could contain the male connection elements and the strut, rod, and
wire construction ele-
ments could contain the female connection elements. This however would result
in a less than
optimum system.
iso One advantage of the radial-hub construction element 290, like the other
construction elements
just described, is that the various construction elements that connect to it
can be inserted and taken
apart in many directions. The hole 288 in the radial-hub construction element
290 can be used for a va-
riety of purposes. Rods can be inserted through the hole 288 or it can be used
to adapt directly to other
construction systems. The radial-hub construction element 290 could be used
used with for example
the paired-snap construction element 100 by using a plate adaptor as shown in
FIGS. 46 to 49.
isi FIGS. 35 to 37 show some of the other radial-hub construction elements
possible such as a 180 de-
gree radial-hub construction element 282, a 90 degree radial-hub construction
element 284, and a
straight radial-hub construction element 286. Other designs with a solid top
surface, or a solid middle
surface at the vertical half point would function just as well.
DESCRIPTION FIG. 38-40~-Strut, Rod, Wire
i32 Another alternate embodiment of the invention is a strut construction
element 300 as shown in
FIG. 38. A male type one split-snap connection element 296 having a pair of
ribs 310 and containing a
side surface 298, is attached to the end of a strut body 294 . The strut body
294 is shown with a hollow
or U-section shape however other configurations could be used. The male split-
snap connection ele-
ment 296 is a new variation of snap-fit connection element which is basically
one-half of the short
split-snap connection element 272. The male split-snap connection element 296
uses the same ridge
128 and the indentation 130. The male split-snap connection element 296 would
ideally use slightly
shorter and stiffer ribs than some previously mentioned designs due to the
short length in the vertical
direction Y of the ribs 310 , the small side surface 298, and the long length
of the strut body 294 com-
pared to its width. Like the beam construction element 280, the joint rigidity
relies on the ridge ramp
32
CA 02361993 2003-02-27
132 pulling the side surface 298 against a side surface 292 of the radial-hub
construction element 290.
Struts are often used to build space-frame type of structures and are designed
to be reasonably stiff.
i33 Another alternate embodiment of the invention is a rod construction
element 302 as shown in FIG.
39. It would use the male split-snap connection element 296 and a flexible rod
body 304. Such a con-
struction element could be snapped onto various construction elements to
produce imaginative de-
signs with multiple arcing shapes.
isa Another alternate embodiment of the invention is a wire construction
element 306 as shown in
FIG. 40. It would be identical to the rod construction element 302 but instead
of a rod body 304, a
much narrower flexible wire body 308 would be used. Such a construction
element would be useful in
constructing structures that use cables such as toy suspension bridges.
DESCRIPTION-FIG. 42-44-Panels
iss Another alternate embodiment of the invention is a panel one construction
element 312, illus-
trated in FIG. 41. A thin sheet 314 is used as the panel. The male connection
element 102 and the fe-
male connection element 104 used are identical to that shown in FIG. 1. The
height in the vertical
direction Y of all panel construction elements would ideally be the same as
the paired-snap construc-
tion element 100, which would allow panel construction elements to be engaged
directly to the block
shaped paired-snap construction element 100 and also the single-snap
construction element 250.
Taller panels might be more desirable, however the shorter panel construction
elements are easier to
mold and are more modular than taller panel construction elements especially
for toy construction
systems.
~sb Another alternate embodiment of the invention is a panel two construction
element 320, illus-
trated in FIG. 42. This type of panel element can be considered a variation of
the beam construction el-
ement as shown in FIG. 30 except it would be generally taller. The panel two
construction element 320
is hollow and uses the same stud wall 110 as the paired-snap construction
element 100. It also uses the
same male connection element 102 and the female connection element 104 as
shown in FIG. 1. The
stud walls 110 allow the panel two construction elements 320 to be assembled
to other panel two con-
struction elements 320 without mating to block style construction elements on
the sides.
i3~ Another alternate embodiment of the invention is a panel three
construction element 316, illus-
trated in FIG. 43. A hollow type cross section is used which has a horizontal
divider 318 to stabilize the
walls. The panel three construction element 316 is a variation of the split-
snap construction element
270 which is shown in FIG. 31, and uses female split-snap connection elements
264 on each edge.
33
CA 02361993 2003-02-27
Long split-snap construction elements 274 or alternatively the short split-
snap construction elements
272 could be used to connect the panel three construction elements 316
together at the edges. The ad-
vantage of this system is that many panels can be engaged side-by-side without
requiring any block
construction elements. Also the long split-snap construction elements 274
would not be visible once
assembled.
iss Another alternate embodiment of the invention is a panel four construction
element 322, illus-
trated in FIG. 44. This panel four construction element 322 is similar to the
panel three construction el-
ement 316 and the split-snap construction element 270. Instead of using a
continuous female
split-snap connection element 264, a female type two panel tab 324 with a
series of gaps 326 between
panel tabs 324 is used instead. This allows the tall panel four construction
element 322 to be molded in
a more optimum direction where the draw of the mold would now be perpendicular
to the large faces
of the panel. The gaps 326 are interspersed between each of the panel tabs
324, such that where the gap
326 occurs, there is no panel tab 324 in the horizontal direction X. Each
panel tab 324 has a groove 328
and projection 168. Long split-snap construction element 274 could be used to
connect the panel four
construction element 322 edge to edge with panel tabs 324 touching each other.
The gaps 326 however
would be visible and so this method may be more ideal for toy sets. Ideally
the panel four construction
element 322 could be engaged to block walls made of the split-snap
construction elements 270. In this
case, each panel tab 324 should correspond to the height of one split-snap
construction element 270.
Using long split-snap construction elements 274 would enable the panel four
construction element 322
to be engaged to each other or to posts or blocks. Ideally the projections 168
would be centrally located
on the panel tab 324 to mate with the indentations 130 in the long split-snap
construction element 274.
i39 Another alternate embodiment of the invention is a panel five construction
element, not shown,
which would use staggered male type one panel tabs with outward facing ridges.
Now the panel is re-
ally a variation of the long split-snap construction element 274 which could
be engaged together with
variations of the split-snap construction element 270.
iao Tall variations of some of the panel construction elements mentioned could
be manufactured by a
variety of processes such as extruding or machining but these processes might
require specialized ma-
chinery to be able to create the indentations 130 or the projections 168
during the machining operation.
DESCRIPTION-FIG. 45-49-Plates
jai Another alternate embodiment of the invention is a plate construction
element which is essen-
tially one side wall of the paired-snap construction element 100 or the single-
snap construction ele-
34
CA 02361993 2003-02-27
ment 250. Such a plate construction element could be engaged onto the sides of
regular construction
elements such as the paired-snap construction element 100. The plates could
contain features attached
or molded on to them. A stud plate construction element 330 is shown in FIG.
45. A stud 332 in the
form of a split snap-pin, which is known in the art, could be used to connect
wheels or other
accessories onto construction elements.
iaa Another alternate embodiment of the invention is a sidepin plate
construction element 334, which
has a side pin 336 as shown in FIG. 46. This side pin 336 could be used to
connect the radial-hub con-
struction element 290 to the paired-snap construction element 100 or to
connect to components of
other construction sets such as "K'nex" or "Znap".
ia3 Another alternate embodiment of the invention is a tab plate construction
element 340, which uses
a protruding plate 338 containing a plurality of holes 342 as shown in FIG.
47. The plate 338 and the
holes 342 could be used to connect to a variety of plates and fittings of
other construction sets such as
"Mechano".
iaa Another alternate embodiment of the invention is a split plate
construction element 350, shown in
FIG. 48. A plate 344 with a plurality of holes 346 can be permanently attached
to a variety of construc-
tion parts such as a floor panel 348, beams, cabinets, or shelving, using
screws or for example by
welding or gluing.
ias Another alternate embodiment of the invention is a window construction
element 352 as is shown
in FIG. 49, which uses a series of single-snap plates 354 attached to a window
356.
DESCRIPTION-FIG. 50-52-Wedge Spacer
~a6 Another embodiment of the invention is a wedge spacer construction element
360, shown in FIG.
50 to 52, which can be inserted between any male ribs which contain the rib
cavity 138. One of the ad-
vantages of the basic connection design of the paired-snap construction
element 100 is that the male
connection element 102 and the female connection element 104 fit neatly into
spaces in the other's fea-
tures. When the paired-snap construction elements 100 have been engaged
together, nearly all the
space that is left in the connection area is the neat rectangular rib cavity
138 as is shown in FIGS. 4 and
7. The wedge spacer construction element 360 can be inserted into this rib
cavity 138 to prevent the
ribs 126 from bending inwards, thereby creating a much stronger connection
than without.
ia~ The wedge spacer construction element 360 can be made of any semi-rigid to
rigid material. If it is
made of a semi-rigid resilient deformable material, it can provide additional
connection strength, but
the construction elements can still be taken apart in the normal way. The
wedge spacer construction e1-
CA 02361993 2003-02-27
ement 360 could be sized so that the friction between its surfaces and those
of the rib cavity 138 bound-
ing it are sufficient to prevent any movement after insertion. An alternate
way to keep the wedge
spacer construction element 360 in position when the construction elements are
engaged is by using a
protrusion 362 on the ends of the wedge spacer construction element 360 which
fits into a rib notch
364 in the insides of the ends of the rib 126. Each end of the wedge spacer
construction element 360
should contain a wedge spacer radius 358 to allow for easier insertion into
the rib cavity 138. The
wedge spacer construction elements 360 used in small toy construction sets
ideally would be made of a
non-toxic, dissolvable, and even edible material.
tas A long wedge spacer construction element 366 is shown in FIG. 52. This
long wedge spacer con-
struction element 366 can be used to connect construction elements together
that are above or below
without the need of other types of connection elements on the top and bottom
faces.
DESCRIPTION-FIG. 53-56-Rotators
~a9 Another alternate embodiment of the invention is a split-snap rotator 370
as shown in FIG. 53.
This type of connection element is basically the short split-snap connection
element 272 which is split
so that a pair of side C ribs 368 and a pair of side D ribs 372 are set at 90
degrees to each other. Any
other angle could be used as well. The split-snap rotator 370 may be used to
engage construction ele-
ments together at various angles to one another and allows construction to
proceed at a different angle.
The split-snap rotator 370 can be molded in one piece or welded together for
larger construction
elements.
iso Another alternate embodiment of the invention is an XZ rotator 374 as
shown in FIG. 54. The XZ
rotator 374 is composed of two parts. A side E 376 contains an eight-sided
projection. Any number of
sides could be used as well. The side E 376 mates by friction or snap ridges
into an eight-sided side F
378. By separating side E 376 and side F 378, they can be rotated at various
angles and re-engaged.
The XZ rotator 374 shown contains female split-snap connection elements 264,
however many differ-
ent connection elements could be used.
isi Another alternate embodiment of the invention is a Y rotator 380 as shown
in FIG. 55. A side G
382 fits by friction or snap ridges into a side H 384. By separating side G
382 and side H 3$4, the con-
struction elements can be rotated at various angles and re-engaged.
is2 Another alternate embodiment of the invention is a pivot rotator 390 as
shown in FIG. 56. A side J
386 is engaged to a side K 388 by a pin 392, which allows the joint to rotate
either freely or with some
friction. Alternately a knuckle joint or other swivel arrangement could be
used.
36
CA 02361993 2003-02-27
DESCRIPTION-FTG. 41-52--Other
iss In this section a variety of additional embodiments of the invention are
shown. Another alternate
embodiment of the invention is a robot hand construction element 394 engaged
to a beam or strut con-
struction element for a toy construction set as shown in FIG. 57. A whole
variety of other features
could be engaged in a similar way.
is4 It has already been mentioned that the paired-snap construction element
100 contains features that
allows it to be engaged to other toy construction sets. FIG. 58 shows some of
the toy construction sys-
tems that can be joined to the paired-snap construction element 100. If the
stud wall 110, the inner wall
stud contacts 124, and the tubular wall stud contacts 118 are the same
dimensions as that of "Lego
Duplo" 396, then "Lego Duplo" 396 can be engaged to the top or bottom of
paired-snap construction
element 100. As well, the stud walls 110 contain the stud cavities 112 that
mate with the central tubes
of "Lego Classic" 398 and allows "Lego Classic" 398 to be engaged to the top
of the paired-snap con-
struction element 100. Some other toy blocks available such as "Morphun" 402
also uses the same stud
walls 110 and can be engaged to the top or bottom of paired-snap construction
element 100. Toy
blocks such as "Kitslink" 404 have a different spacing between studs as "Lego
Duplo" 396. A stud
adaptor construction element 400 that has "Kitslink" 404 dimensioned cavities
below and "Lego
Duplo" 396 studs above would allow "Kitslink" 404 blocks to connect onto the
bottom of "Lego
Duplo" 396 compatible parts. Because the horizontal dimensions of "Kitslink"
404 are not the same as
"Lego Duplo" 396, only one stud adaptor construction element 400 would be used
to start constructing
off in the new "Logo Duplo" compatible system.
ass Another alternate embodiment of the invention not shown is to use the
plate construction ele-
ments shown previously in FIG. 4S to 49 to connect to other construction
systems that have side link-
ing connection elements such as "Morphun" 402 and Kitslink"404. One side of
the plate construction
element would contain snap-fit connection elements according to the invention
and the other would
contain dovetail fasteners for the other systems.
is6 An additional aspect of the invention is a pry tool 410 as shown in FIG.
59. When a large amount
of construction elements such as the paired-snap construction element 100 have
been assembled to-
gether in a large cubic solid, it can become difficult to pull the paired-snap
construction elements 100
apart. The easiest way to split large cubic solids is to pry apart the studs
first and peel apart whole lay-
ers of the paired-snap construction elements 100. The paired-snap construction
element 100 has
rounded corners. The pry tool 410 has a pointed end which is designed to help
split the paired-snap
construction elements 100 apart. The painted end is rounded with a tip radius
408 to prevent harm to
37
CA 02361993 2003-02-27
children if used with toy sets, but can still be pushed between the top
surface 108 and the bottom sur-
face 114 of the paired-snap construction elements 100. A slight twisting
motion along the axis of the
pry tool 410 at various places allows whole layers of paired-snap construction
elements 100 to be re-
moved. It is now much easier to separate the paired-snap construction elements
100 at the sides. The
pry tool 410 also has a wedge spacer punch 406 which can be used to push out
or insert the wedge
spacer construction element 360.
1s~ Another alternate embodiment of the invention is a vertical hole
construction element 420 as
shown in FIG. 60. This construction element would be identical to the paired-
snap construction ele-
ment 100 except that it contains a vertical hole 412 and a countersink 414.
The vertical hole 412 would
allow a long snap pin 416 or a threaded rod 418 to pass through them as is
shown in FIGS. 61 and 62. In
toy sets, such long snap pins 416 could anchor two vertical hole construction
elements 420 together, as
the holding force of the stud connection elements is not very much. In larger
construction, the threaded
rods 418 could pass through the vertical hole 412 which would allow entire
walls to be anchored to the
foundation.
iss The construction elements may be different colors, to allow the creation
of mufti-colored con-
structions. When used as an educational toy, construction elements without
studs or other connection
elements on the top surface and having a letter 422 of the alphabet printed or
molded on them could be
used, as shown in FIG. 63. Words could be spelled by connecting blocks with
different letters together.
Similarly, numbers and arithmetic functions could be printed on the blocks in
order to teach the funda-
mentals of math. Alternately, each construction element could contain parts of
a picture for a puzzle.
Signs could be constructed in the same way, which could easily be changed. It
is contemplated that
even more educational and commercial uses could be made of the construction
elements in this way.
~s9 Another alternate embodiment of the invention is a rib with slots 424 as
shown in FIG. 64. A slot
427 is used as an alternative to the indentations 130 used on most of the
construction elements de-
scribed so far. The slot also includes an upper slot ramp 428 and a lower slot
ramp 429 similar in angle
to the indentation I30 of the paired-snap construction element 100. Instead of
the slot 427 being only
the length in the longitudinal direction Z of the ridges, the slot 427 could
extend the full length in the
longitudinal direction Z of the ribs 426 which would separate them into two
parts.
i6o Another embodiment of the invention is the paired-snap channel
construction element 430 shown
in FIG. 65. The paired-snap channel construction element 430 is identical to
the paired-snap construc-
tion element 100 of FIG. 1, except that while the sides of the paired-snap
construction element of 100
are flat between the connection elements, the sides of the paired-snap channel
construction element
38
CA 02361993 2003-02-27
430 have a channel 432. When two or more paired-snap channel construction
elements 430 are en-
gaged together on the sides, the channels 432 placed together become
symmetrical apertures. Two
paired-snap channel construction elements 430 could be engaged together around
a tubular column
434. If grooves or ledges are provided in the channels 432, they could
interact with a ridge 435 of the
tubular column 434 to keep the paired-snap channel construction elements 430
from sliding down the
length of the tubular column 434. A second variation of this is a single-snap
channel construction ele-
ment 440, shown in FIG. 66, which uses a single-snap connection element on
each face rather than
paired-snap connection elements. A pair of ribs 438, are essentially like
those of the single-snap
construction element 250, except the rib cavity consists of a channel 436
which is very wide.
i6i Another alternate embodiment of the invention is a construction element
442 shown in FIG. 67.
This design is somewhat similar to the single-snap construction element 250 in
that it only has one
connection element on each side, but it is different because it has no anti-
twist bars 162 or depressions
142. This construction element 442 is really a block embodiment of the radial-
hub construction ele-
ment 290 and the strut construction element 300, and uses the same female
split-snap connection ele-
ments 264 and male split-snap connection elements 296. Paired-snap connection
elements could also
be used with this configuration, however there is a limited amount of room
between the stud walls 110.
i62 Another alternate embodiment of the invention is a construction element
443 shown in FIG. 68.
This construction element 443 is identical to the paired-snap construction
element 100 but is missing
the anti-twist bars 162. A connection element 444 only extends to the side
surfaces of the construction
element. This design of construction element might be considered to be
slightly easier to assemble
than the paired-snap construction element 100, but not having anti-twist bars
162 results in a lot more
stress being placed on the extended ribs 126. This is especially a problem if
a single connection ele-
ment is used per side. It is also difficult to provide a female recess that is
sufficiently divergent as is il-
lustrated by the example shown in FIG.12B. The ends of the ribs must have more
of a taper, which can
result in a longer rib. Also the depressions 142 of the male connection
element 102 are not filled up
when two construction elements are engaged together and this results in a less
appealing look.
DESCRIPTION-Conclusions, Ramifications, Scope
i63 The advantages of the snap-fit connection, compared to the usual dovetail
connection, is best un-
derstood by looking at FIG. 69. This shows a basic male type one snap-fit
connection element 446 su-
perimposed over a female dovetail connection element 448. Such a snap-fit
connection element 446
39
CA 02361993 2003-02-27
could be much the same size as the dovetail connection element 44.8. With most
materials, if the fe-
male dovetail connection element 44.8 was separated from the male dovetail
connection element, the
narrowed opening of the female dovetail connection element 448 would need to
stretch so far that the
joint would be damaged. Compare this to the ribs of the snap-fit connection
element 4.46, which can
still hold quite tightly at first, but when excessive force is encountered,
the male snap-fit connection el-
ement 446 could break away from the female connection element, without being
damaged. It is also
easier to design the snap-fit connection 446 with a higher angle of contact
that adds to its holding
power. For weaker materials, a dovetail connection spreads the load over a
wider area, but with materi-
als such as plastics, the snap-fit connection is a better choice. Dovetail
connections are often used be-
cause they are simple shapes while snap-fit connections are considered more
exotic mechanisms that
need much more careful design.
ma Another advantage of the snap-fit connection system of the invention is
that while it can secure a
connection in six spatial directions, can be made to engage and separate in
many directions, is easy to
assemble, can be used to build in many directions, and can be applied to a
very wide variety of con-
struction elements, the basic embodiments of the invention can still be
produced in the most inexpen-
sive type of single direction mold with only one fixed and one moving die and
a simple ejection
system. On the paired-snap construction element 100, the ribs 126 contain
indentations 130 which are
a problem on single direction molds because the corresponding projections in
the mold would be in the
way of the ribs 126 sliding out of the mold. If side cores would be used, this
could result in 32 side
cores being needed for an 8-cavity mold. The advantage of the invention is
that cores that form the rib
cavity 138 between the pair of ribs 126, can be fastened to the moving half of
a two-part mold. In the
preferred molding method, the moving half of the mold only contains features
to mold the top of the
paired-snap construction element 100 and not the snap-fit connection elements
on the sides. When this
moving half of the mold moves away from the fixed half of the mold, it pulls
out the cores. This allows
the ribs 126 to flex into this space that now exists between the pair of ribs
126 during the part ejection.
The ribs 126 can now temporarily bend and pass over the projections in the
mold.
ibs It is contemplated that various embodiments of the invention could be made
of various materials
and manufactured by various methods. Smaller construction elements would
preferably be molded of
a plastic material. In the case where the ribs 126 are a permanent part of the
construction element, such
as the paired-snap construction element 100, it is usually necessary to make
the entire construction ele-
ment of a flexible material. Other construction elements such as the split-
snap construction element
270 could be made of a rigid material because the short split-snap
construction element 272 or long
CA 02361993 2003-02-27
split-snap construction element 274 can be made of a different and more
flexible material. So, such
construction elements as the split-snap construction element 270 could also be
made of materials such
as wood, metal, concrete, and ceramics. Preferably, the different mating
material will have a reason-
ably low coefficient of friction or could be coated or penetrated with a
suitable material to reduce the
friction.
m With toy construction elements, it was found that a lubricant added to
plastics such as polypropy-
lene made the construction elements much easier to assemble. The lubricant
used in toy construction
elements so far has been a lubricant called Erucamide, which is basically of
the Fatty Acidamide
chemical family derived from cattle beef tallow. This is a relatively
inexpensive lubricant, has a long
life, and is also considered safe for children to touch or put in their
mouths. Acetal, it was found, had a
low enough coefficient of friction in its native form, but this material is
considerably more costly and
shatters more easily than polypropylene.
i6~ The versatility of the type one and type two connection elements of the
invention means that it can
be used with a multitude of construction elements of varying size and shape.
It is contemplated that
smaller construction elements for use in toy construction sets will be one of
the uses of the invention.
These may be sold as various construction sets. However, larger construction
elements for use in the
construction industry could be produced. The construction elements would be
useful in a variety of
fields such as, construction, toys, educational, machinery, products, jigs,
two and three dimensional
art, and signs.
i6a Though many different embodiments of the invention have been shown so far,
there are still many
possible designs that have not been shown. Some of these different embodiments
will be shown with
the aid of generic diagrams. When two snap-fit connection elements are engaged
in the longitudinal
direction Z, the male ribs must bend inwards towards each other before
expanding outward again into
the female groove. Some sort of angled surfaces must be used to compress the
ribs together. FIG. 12
shows three different embodiments of the invention that can be used to
accomplish this. In each case a
male type one connection element is entering a female type two connection
element. In FIG. 12A, a di-
vergent recess 227 has a pair of divergent opposed walls 226 angled so that
the female entrance is
wider. This feature alone can be used to gradually compress even a pair of
square ribs 224 with a
square rib 225 when entering the divergent recess 227. A second method to
gradually compress the
ribs together is to use a square recess 231 with a square recess edge 230
along with a pair of angled ribs
228 which uses a tapered rib 229 as shown in FIG. 12B. The disadvantage of the
latter method is that
the length of the angled ribs 228 must usually be increased in the
longitudinal direction Z due to the ex-
41
CA 02361993 2003-02-27
tra length of the tapered rib 229. A third method to gradually compress the
ribs together is to use a par-
allel recess 236 and a pair of parallel opposed walls 235 and a pair of
radiused ribs 232 having a
radiused rib 233 as shown in Fig 12C. The resulting friction is generally
higher than using flatter angu-
lar surfaces however. A combination of the different methods just described
could be used. For exam-
ple the divergent recess 22? could be used with the radiused rib 233, as well
as using a recess radius
234. The paired-snap construction element 100 uses this method, which result
in a smoothly operating
connection within tight space constraints.
i69 The ribs 126 of the paired-snap construction element 100 are preloaded
such that when they are
engaged within the groove 154, they exert a force acting outward against the
angled groove ramps 157
shown in FIG. 7. The greater this preload force is, the less the connection
will start opening up gradu-
ally when increased forces attempt to separate the connection elements. With
metal materials, this
preload force could be very high, but plastic materials often have poorer
creep characteristics. A high
degree of preload makes it hard to slide the paired-snap construction elements
100 together with a ver-
tical engagement 240 or even to locate the connection elements by feel. This
is because the ribs 126
need to be spread apart further than the groove 154 before the start of the
engagement. It is now a
steeper part of the top radius 122 or the bottom radius 123 around the groove
154 entrance that helps to
guide the ribs 126 in. Preload is not as much of a problem with a longitudinal
engagement 237 as the
female recess 152 can be quite divergent. A small amount of preload, roughly
25°l0 of the maximum
flexing force experienced during engagement, works best for toys. This is good
because polypropy-
lene generally has poorer creep characteristics than materials such as Acetal,
which are often specified
for such connection elements when a high amount of preload is used. For
connection elements where
plastics such as Acetal or metals can be used, the connection elements could
be designed to have a
much higher level of preload.
0o Different embodiments of the invention can use various angles of the ridge
ramp and groove
ramp. FIG. 8 shows top views of the male type one connection element with
various angles of the ridge
ramp and FIG. 9 shows top views of the female type two connection element with
various angles of the
groove ramp. A 45 degree ridge ramp angle 184 along with a 45 degree groove
ramp angle 192 is ideal
for many applications. These are the angles that are also used in the paired-
snap construction element
100. Calculations show that with lubricated polypropylene and the 25°lo
preload mentioned earlier,
this angle resulted in a good compromise between easy separation of two
construction elements, while
at the same time holding the construction elements together with sufficient
force. Somewhere around
60% of the maximum breakout force is required to begin to move the connection
apart. For other pur-
42
CA 02361993 2003-02-27
poses however, other angles can be used but some of the features mentioned for
the paired-snap con-
struction element 100 of FIG. 1 might be lost. For example with a 90 degree
ridge ramp angle 186
along with a 90 degree groove ramp angle 194, it would be almost impossible to
separate the connec-
tion in the longitudinal direction Z. A bulbous ridge ramp 190 combined with a
bulbous groove ramp
198 results in the angle of contact changing more quickly on separation than
the 45 degree ridge ramp
angle 184 and manufacturing tolerances result in varying connecter
characteristics. Of course the an-
gles of the ridge ramp and groove ramp can be different, but to prevent
scuffing and roughening of the
contact surfaces, ideally they should be the same.
m Different embodiments of the invention can also use various angles of the
indentations and pro-
jections. FIG. 10 shows longitudinal views of various angles of the
indentation ramps and FIG. 11
shows longitudinal section views of various angles of the projection ramps.
The indentations and pro-
jections keep the ribs from sliding along the grooves in the vertical
direction Y. FIG. IOA and 11A
show a 45 degree indentation upper ramp 200 and a 45 degree indentation lower
ramp 202 as well as a
45 degree projection upper ramp 212 and a 45 degree projection lower ramp 214.
For toys, these angles
result in a good compromise between being able to slide the connection apart
in both vertical direc-
tions Y with a reasonable force, as well as holding the connection in place.
These are the angles that are
also used in the paired-snap construction element 100. To be able to apply a
greater force downward
along the groove before the connection opens but still retain most desirable
features, a 90 degree in-
dentation upper ramp 204 and 45 degree indentation lower ramp 206 along with a
90 degree projection
upper ramp 216 and a 45 degree projection lower ramp 218 can be used as shown
in FIG. lOB and 11 B.
It is also possible to make a 135 degree indentation upper ramp 208 and a 45
degree indentation lower
ramp 210 along with a 135 degree projection upper ramp 220 and a 45 degree
projection lower ramp
222 as shown in FIG. lOC and I 1 C. The indentation upper ramp now acts like a
hook. A 45 degree in-
dentation lower ramp 210 allows the part to still be made in a simple mold and
allows the construction
elements to still be taken apart by sliding in the vertical direction Y. One
disadvantage of this last vari-
ation with 135 degree indentation upper ramp 208 is that extra clearances are
necessary in the
indentations making the connection sloppy in one vertical direction Y.
oa Of course other ridge, groove, indentation, and projection ramp angles than
suggested here could
be used as well. Not all combination of ramp angles would be easy to mold.
Other combinations are
not generally practical or would even work. For example a combination of a 135
degree ridge ramp an-
gle 188 shown in FIG. 8C along with a 135 degree groove ramp angle 196 shown
in FIG. 9C and any
combinations of indentation and projections shown in FIGS. 10 and 11 would not
work because the
43
CA 02361993 2003-02-27
connection elements could not be pushed together with the longitudinal
engagement 237 or the verti-
cal engagement 240. The 135 degree ridge ramp angle 188 shown in FIG. 8C used
with the 90 degree
groove ramp angle 194 shown in FIG. 9B would be a way of making a strong
connection that still
would work.
as Even while generally conforming to the basic features of the construction
elements described so
far, many more alternate embodiments of the invention are possible. There
could be a variety of differ-
ent top and bottom surface connections other than studs. One alternate stud
connection would be a
snap-fit system using a slight ridge in the stud and a slight undercut groove
in the stud contact area. As
well, the stud can have a groove where it meets the top surface of the
construction element, and the
stud contact can have a projection at the bottom surface. These methods have
already been described
in the prior art. Such connection methods however make it very difficult to
remove large assemblies of
construction elements that have been engaged together with both stud and snap-
fit connections. It is
contemplated that the top and bottom connection elements may be a variety of
shapes and sizes. For
example, in addition to the shape of round studs as illustrated in FIG. 1, the
connections elements
could take the shape of square studs, tabs, a single raised center area, etc.
Preferably the connection el-
ement on the top surface of the construction element would be shaped and sized
so as to mate with
complimentary connection elements on the lower surface of an adjacent
construction element. It is
also possible that some construction elements will have no vertical connection
elements or will have
either top or bottom vertical connection elements. A construction element
without top and bottom
connection elements could be used for the floor of a building, for example.
oa The paired-snap construction element 100 shows the recess 152, groove 154,
and anti-twist bars
162, as well as the ribs 126, ridges 128, and depressions 142 extending the
full height of the construc-
tion element. This results in the strongest connection along with a
construction element that is easy to
use. Realistically, only the groove 154 and the depression 142 must travel the
full height of the con-
struction element in order that a snap-fit connection can be made with either
a longitudinal engage-
ment 237 or a vertical engagement 240 as illustrated in FIG. 13 and 18. The
ribs 126 and anti-twist bars
162 of the invention may be any length to provide a sufficiently rigid
connection.
ms The paired-snap construction element 100 uses connection elements that can
be engaged or sepa-
rated in many different ways. This is ideal. For certain other situations
however, it may be desirable to
use less versatile connection elements due to space constraints for example. A
snap-fit connection ele-
ment could be made that had no means for engaging or separating with a
longitudinal engagement 237,
rather it could only be engaged or separated with a vertical engagement 240.
Such a connection ele-
44.
CA 02361993 2003-02-27
ment could even be limited to engagement in one vertical direction Y due to
the angles of the indenta-
tions and projections. Provided that such connection elements contain the
right combination of
grooves, projections, ridges, and indentations that are claimed, they are
still an embodiment of the in-
vention. Such embodiments would be a good substitute for certain dovetail
connections.
176 FIGS. 70A and 70B show two quite different generic connection element
embodiments of the in-
vention. So far, all the embodiments of the connection element have conformed
to FIG. 70A. This
drawing shows a generic male type one connection element 450" with a pair of
flexible ribs 458, with a
pair of outward facing ridges 462, containing an indentation 464, to be
engaged with a generic female
type two connection element 452, containing a recess 468, and a pair of
opposed walls 470, with a pair
of inward facing grooves 472, containing projections 474, and a generic
connection radius of 466. Be-
cause this male connection element 450 has a rib cavity 460, it is easy to
mold, as a single core can be
pulled out from between the rib cavity 460, allowing the ribs 458 to flex
inward when being ejected
from the mold. The opposed walls 470 being rigid, allows them to be molded
into block type
construction elements.
177 Another less practical but still valid embodiment of the invention is
shown in FIG. 70B. This
drawing shows a generic male type two connection element 454, with a pair of
ribs) 476, with a rib
cavity 490, and a pair of inward facing grooves 478, with a projection 480, to
be engaged with a ge-
neric female type one connection element 456, containing a recess 482, and a
pair of flexible opposed
walls 484, with an inward facing ridge 486, and an indentation 488. The ribs)
476 could also be made
into one rib. This design is not as easy to mold because it would require two
mold parts to be pulled out
from each side of the generic female type one connection element 456 to allow
the opposed walls 484
to flex outward when being ejected from the mold. This design is not as
practical to integrate into block
type construction elements that have half-way sunken connections because,
after engagement two
spaces would be left on each side of the opposed walls 484 instead of one for
FIG. 70A. This doesn't
look as good and results in a total connection that is slightly wider in the
horizontal direction X.
17e FIG. 70 shows the generic male type one connection element 450 to have a
parallel rib cavity 460,
but ribs that have an angled rib cavity 460 or otherwise angled ribs 458 also
conform to the invention.
Ribs 458 pointing together or apart can work provided the contacting angles
are appropriate, but for
most situations nearly parallel ribs have the most advantages. The parallel
rib cavity 460 is often cho-
sen for looks and so a rectangular wedge spacer construction element 360 can
be inserted between the
ribs 458.
179
CA 02361993 2003-02-27
Other connection elements very similar to those described in FIG. 70A and 70B
can be imagined
but are not being claimed as an embodiment of the invention because they would
not be as practical.
Take for example the embodiment of FIG. 70A which was rather made with rigid
ribs and flexible op-
posed walls. Or make the embodiment of FIG. 70B with flexible ribs and rigid
opposed walls. In both
cases the projections in the groove would severely hamper the flexibility of
the ribs or opposed walls.
As well, in both cases, the indentations on the more rigid ribs or opposed
walls would make such a
design difficult to mold.
~so In reality, connection elements are not completely flexible or totally
rigid. Type one connection
elements are the more flexible and type two are the more rigid in the
invention. In the embodiment of
FIG. 70A, the ribs 458 should be substantially more flexible than the opposed
walls 470 and in the em-
bodiment of FIG. 70B, the opposed walls 484 should be substantially more
flexible than the ribs) 476.
While the above descriptions contain many specifics, these should not be
construed as limitations
on the scope of the invention, but as examples of the presently preferred and
alternate embodiments
thereof. Many other ramifications and variations are possible within the
teachings of the invention, as
described above. Thus the greater scope of the invention should be determined
by the appended claims
and their legal equivalents, and not by the examples given.
46
