Foam Panel Toy System

Abstract

A toy system of foam panels having a novel edge design that permits panels to being resistant to separation without the application of an additional force whether orientated in a planar manner, orthogonally or any angle therebetween is described.

Description

BACKGROUND

Closed cell foam panels, typically comprised of neoprene or another suitable elastomeric polymer, having dovetail ends for interlockingly joining multiple panels are well known. Typically, these panels are used as a floor covering often used in children's playrooms and exercise rooms.

The typical prior art panel comprises a top surface that is substantially parallel to a bottom surface separated by the thickness of the panel. The sides of each panel are characterized by alternating trapezoidal-shaped projections and trapezoidal cavities. All the edge sidewalls are orthogonal to the top and bottom surfaces. Further, each side wall segment excepting internal and external radii are substantially planar.

As can be expected, this edge configuration, inhibits two joined foam panels from being easily pulled apart horizontally when placed on a floor, but the two pieces can be easily separated by pulling one piece vertically upwardly relative to the other.

It is known for children to use these foam floor panels/tiles as toys to build structures, such as imaginary buildings and walls comprised of vertically orientated panels joined at 90 degrees relative to each other. Further, the vertical panels can be joined to horizontal underlying or overlying panels to form enclosed structures. Unfortunately, when edges of foam panels of the prior art configuration are joined at 90 degrees, they do not tend to stay together in part making the typical edge configurations of prior art foam panels less than ideal for creating orthogonal joints.

Toy systems using foam panels are also known although in most cases, they involve foam panels cut in shapes other than rectangles and squares that are assembled in a particular manner to make a specific three-dimensional object and often comprise connection means specifically tailored to the specific shapes, configurations and orientations of the panels required to form the specific object. These panels do not typically facilitate the child to create structures of his/her own configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an interlocking foam panel of which a plurality comprises a foam panel toy system according to an embodiment of the present invention.

FIG. 2 is another perspective view of the interlocking foam panel of which a plurality comprises a foam panel toy system according to an embodiment of the present invention.

FIG. 3 is a partial perspective view of the foam panel showing a hemispherical protrusion centered on a face of a panel recess according to an embodiment of the present invention.

FIG. 4 is a partial perspective view of the foam panel showing a hemispherical indentation centered on a face of a panel projection according to an embodiment of the present invention.

FIG. 5 is a top view of the foam panel according to an embodiment of the present invention.

FIGS. 6a-c are perspective views of two foam panels joined together at various orientations according to an embodiment of the present invention.

FIG. 7 is a perspective view of a structure created using the foam panel toy system according to an embodiment of the present invention.

DESCRIPTION

Overview

Embodiments of the present invention comprise a system of foam panels having a novel edge design that permits panels to being resistant to separation (i.e. lockably engaged) whether orientated in a planar manner, orthogonally or any angle therebetween. More particularly, embodiments of panels are characterized by edges having alternating projections and recesses that are configured to interface with recesses and projections on other foam panels that have complementary configured and dimensioned panel edges. Importantly, the configurations of alternating projections and recesses are permit two panels to remain lockably engaged at any relative angle unlike commonly known foam floor panels, which are configured to remain lockably engaged only when the panels are arranged in a generally planar fashion.

The foam panels are typically provided as a set of similar panels forming an embodiment of a toy system for constructing structures, such as walls, facsimiles of buildings, and whatever else creative young minds can conjure.

Terminology

The terms and phrases as indicated in quotes (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document including the claims unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.

The term “or” as used in this specification and the appended claims is not meant to be exclusive, rather the term is inclusive meaning “either or both”.

References in the specification to “one embodiment”, “an embodiment”, “a preferred embodiment”, “an alternative embodiment” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all meant to refer to the same embodiment.

The term “couple” or “coupled” as used in this specification and the appended claims refers to either an indirect or direct connection between the identified elements, components or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.

Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, upper, lower, vertical, horizontal, back, front, lateral, outwardly, and upwardly are relative to each other and are dependent on the specific orientation of an applicable element or article, and are used accordingly to aid in the description of the various embodiments and are not necessarily intended to be construed as limiting.

Unless otherwise indicated or dictated by context, the terms “approximately” and “about” mean +−20%. Unless otherwise indicated or dictated by context, the term “substantially” means +−10%. The term “generally” means for the most part

As used herein an “edge” of the panel refers to one side of a generally rectilinear-shaped panel that also may include either projections or recesses formed thereat. In other words, an edge as defined herein need not be linear, but can comprise alternating projections and recesses.

As used herein the term “projection” refers to a portion of the planar panel located at an edge thereof that extends outwardly from the immediately adjacent portions of the panel and has spaced parallel left and right sides that are substantially square relative to the edge portions of the immediately adjacent portions of the panel. A projection also includes an outwardly facing side that spans between the left and right sides and is substantially orthogonal to the left and right sides. The outwardly facing side is a typically the most outward portion of the associated edge of the panel.

As used herein the term “recess” refers to a portion of the planar panel located at an edge thereof that extends inwardly from the immediately adjacent portions of the panel and has spaced parallel facing left and right sides that are substantially square relative to the edge portions of the immediately adjacent portions of the panel. A recess also includes an outwardly facing side that spans between the left and right sides and is substantially orthogonal to the left and right sides. The outwardly facing side is a typically the most inward portion of the associated edge of the panel.

An Embodiment of a Foam Panel of a Foam Panel Toy System

FIGS. 1-5 illustrate an embodiment of a typical foam panel 10. The panel when measured from the outmost portions of each edge 16-22 is generally of a square shape, although panels of different shapes are known. The panels typically have spaced apart planar top and bottom surfaces 12 & 14 that are spaced apart to define a thickness. The illustrated panels are about 0.50″ thick, but thicknesses can vary substantially depending on the particulars of a specific design or configuration.

The panels 10, which in one embodiment are molded, are comprised of a soft, compressible and resilient foam material that in its particular design configuration is substantially stiff to retain its planar panel configuration when in use as part of a toy building system 46 (see FIG. 7 wherein a plurality of panels comprising a system have been assembled into a building), but that will give and bend when any significant load is applied, such as might be the case if a panel were used by a child to hit a playmate or to throw the panel at the playmate. In one embodiment, the panels comprise an EVA foam with a Shore C hardness of about 40-45. Other foam materials and other manufacturing methods can be used; however, molding the panels in a single operation is ideal for the formation of the protrusions 40 and indentations 42 that help secure the panels together at a variety of angles as will be described in detail herein below.

The left, upper, right, and lower edges 16-22 of the panels are characterized by generally alternating outwardly extending projections 24 and inwardly disposed recesses 26. In the illustrated embodiment panel 10, the left edge 16 and opposing right edge 20 are described as having two recesses 26; whereas, the upper and lower edges 18 & 22 are described as having two projections 24. As is important to the functionality of the toy panel system, each of the left and right substantially square sides 28,30,34 & 36 of the projections and recesses will include one of a protrusion or indentation centered thereon.

As an aside, it is to be appreciated that each of the edges of the panel can be described differently while pertaining to the identical configuration. For instance, the square foam panel can be alternatively described as having three alternative projections extending outwardly from the left and right edges bounding two recesses, and having two alternative projections extending outwardly upper and lower edges spaced that are spaced inwardly from the corner intersections with the respective left and right edges and each bound one recess. It is to be further appreciated that these alternative projects would not all have protrusions and indentations centered on their substantially square sides.

Each of projections 24 are of the same size as are each of the recesses 26. Furthermore, the depth of each of the recesses is identical to the height of each of the projections, and importantly these heights and depths are the same dimension as the panel's thickness. This results in the substantially square sides 28,30,34 & 36 mentioned above. Additionally, the widths of the projections and recesses are also substantially similar. Accordingly, and importantly, each of the protections fit snuggly within the recess of another similarly sized panel.

As best shown in FIGS. 3 and 4, each of the square left and right sides 28,30,34 & 36 include one of a protrusion 40 or indentation 42 that is substantially centered about the center point of the respective side. As illustrated the protrusions and indentations are hemispherical and relatively small compared to the size of the associated sides. The shape of the protrusions and indentations can vary as can their size relative to the sides. However, the indentations are typically sized to receive corresponding protrusions from another panel 10 snuggly therein.

As shown in the illustrated embodiment panel 10, the left and right sides 34 & 36 of the recesses 26 have hemispherical protrusions centered on them, while the left and right sides 28 & 30 of the projections 24 have hemispherical indentations centered on them. As can be appreciated the locations of the protrusions and indentations can be switched in variations of the panel. Further, variations are known wherein one side of a recess and projection has an indentation while the other opposing side has a protrusion. The key consideration in the locations of the protrusions and indentations is that the protrusions on one panel correspond to the indentations on another panel along sides that are to be joined. Accordingly, when two panels are joined along an edge, the interaction between the protrusions and indentations act to lockably engage the panels in a desired position relative to each other.

FIG. 6A shows two panels 10 joined in a planar relationship. FIG. 6B shows a side view of two panels joined at 90 degrees. Finally, FIG. 6C shows two panels joined at 45 degrees. In each instance, because the left and right sides 28,30,34 & 36 of the projections 24 and recesses 26 are square with a side dimension the same as the panels' thicknesses, the protrusions of one panel remain seated and retained in the other panel's indentations. Effectively, joined panels can be rotated relative to each other to any desired angle and still remain engaged.

The protrusions 40 and indentations 42 are typically formed during the panels molding process, and as such, exhibit the same softness and resiliency as the rest of the panel. Accordingly, the protrusions compress along a joining edge when two panels are being connected, and correspondingly compress when joined panels are pulled apart at a joining edge. As can be appreciated by varying parameters such as the hardness of the foam, the size of the protrusions and shape of the protrusions, the force required to either join of separate panels can be adjusted to a desired level.

Graphics maybe printed or embossed on one or both the top and bottom surfaces. The graphics 44 can comprise any desired pattern or images. In the illustrated embodiment, the graphics are abstract but when panels are combined can give the impression of a side of a building with windows distributed thereon.

An Embodiment of the Foam Panel Toy System

As can be appreciated from the description of the illustrated embodiment above, each foam panel 10 is configured to be joined with other similar panels along its edges to fabricate toy structures. In other words, a plurality of similar panels all having edges of similar configurations comprise a foam panel toy system that permits a child to create structures, such as a building 46 as shown in FIG. 7, and play with the panels and foam panel structures. In one embodiment of a toy system all the panels are the same size, such as square. In other embodiments, several sizes of panels may be provided wherein the panels all have similar sized projections and recesses. The panels are typically rectilinear but panels that are triangular and other sizes having at least one edge comprising recesses and/or projections are also known.

Variations and Other Embodiments

The various embodiments and variations thereof, illustrated in the accompanying Figures and/or described above, are merely exemplary and are not meant to limit the scope of the invention. It is to be appreciated that numerous other variations of the invention have been contemplated, as would be obvious to one of ordinary skill in the art, given the benefit of this disclosure. All variations of the invention that read upon appended claims are intended and contemplated to be within the scope of the invention.

For instance, the protrusions and indentations can be of other shapes other than hemispherical as suitable including, but not limited to, rectilinear, cylindrical and conical. The protrusions and indentations can be made by any suitable means. In some variations, the protrusions and indentations can be molded integrally with the panels. In yet other variations the indentations can be post molded especially when the foam comprising the panel is a thermoplastic material. The indentations and protrusions can be cut from the material in a post-panel fab operation. The protrusions in yet other embodiments can added after panel fab and adhesively, mechanically or thermally affixed to the faces.

Claims

1. A generally rectangular foam panel having left, right, top and bottom edges and a planar upper surface spaced a thickness from a parallel lower surface, the opposing left and right edges including a plurality of rectangular projections extending outwardly from the respective edge, the opposing top and bottom edges including a plurality of rectangular recesses extending inwardly from the respective edges, each projection having substantially square left and right projection sides orthogonally intersecting with the edges of an outwardly facing projection side, each recess having substantially left and right recess sides orthogonally intersecting with an outwardly facing recess side, the projections and the recesses having similar dimensions with lengths of edges of the left and right projections sides and edges of the left and right recess sides being the thickness in length wherein (i) at a center point of each of the left and right recess sides, one of a protrusion projects outwardly or an indentation extends inwardly, and (ii) at a center point of each of the left and right projection sides, one of a protrusion projects outwardly or an indentation extends inwardly, each indentation being sized to receive a corresponding protrusion on another similarly configured foam panel therein.

2. The foam panel of claim 1, wherein each of the recesses and projections are generally hemispherical.

3. The foam panel of claim 1, wherein the panel is generally square.

4. The foam panel of claim 1, wherein the left and right recess sides each have a protrusion, and the left and right projection sides each have a recess.

5. The foam panel of claim 1 consisting essentially of EVA foam.

6. The foam panel of claim 5, wherein the EVA foam has a Shore C durometer of about 40-45.

7. The foam panel of claim 1, wherein the top and bottom sides each include two recesses, and the left and right sides each include two projections.

8. The foam panel of claim 1, wherein the thickness is about 0.5″.

9. The foam panel of claim 1, wherein an overall size of the foam panel is about 7.875″ by 7.875″ with the recesses extending inwardly about 0.50″ and the projections extending about 0.50″ outwardly.

10. The foam panel of claim 1, wherein a graphical design is imprinted on the top side.

11. The foam panel of claim 1, wherein the recesses and projections are molded into the foam panel during creation thereof.

12. A toy system comprising in combination of eight or more foam panels of claim 1, all of the same size and dimensions.

13. A toy system comprising in combination of eight or more foam panels of claim 1 including a first plurality of foam panels having a first overall size and a second plurality of panels having a second overall size, wherein the projections and recesses of each of the first and second panels are all of the same size and dimensions.

14. A generally square foam panel comprising EVA having a Shore C hardness of about 40-45, the foam panel having left, right, top and bottom sides and a planar upper surface spaced a thickness from a parallel lower surface, the opposing left and right sides including a plurality of rectangular projections extending outwardly from the respective side, the opposing top and bottom sides including a plurality of rectangular recesses extending inwardly from the respective sides, each projection having substantially square left and right projection sides orthogonally intersecting with the edges of an outwardly facing projection side, each recess having substantially left and right recess sides orthogonally intersecting with an outwardly facing recess side, the projections and the recesses having similar dimensions with lengths of edges of the left and right projections sides and edges of the left and right recess sides being the thickness in length wherein (i) at a center point of each of the left and right recess sides, one of a hemispherical protrusion projects outwardly or a hemispherical indentation extends inwardly, and (ii) at a center point of each of the left and right projection sides, one of a hemispherical protrusion projects outwardly or a hemispherical indentation extends inwardly, each indentation being sized to receive a corresponding protrusion on another similarly configured foam panel therein, and (iii) a graphical design is imprinted on the top side.

15. The foam panel of claim 14, wherein the left and right recess sides each have a protrusion, and the left and right projection sides each have a recess.

16. A toy system comprising in combination of eight or more foam panels of claim 14, all of the same size and dimensions.

17. A method of using the toy system of claim 14 comprising joining a first panel of the eight or more foam panels to a second panel of the eight or more panels along corresponding first edges of the panels, wherein the first and second panels are orientated in a planar relationship.

18. A method of using the toy system of claim 14 comprising joining a first panel of the eight or more foam panels to a second panel of the eight or more panels along corresponding first edges of the panels, wherein the first and second panels are orientated in an orthogonal relationship.

19. The method of claim 17, comprising joining a third panel of the eight or more foam panels to the first panel along a first edge of the third panel and a second edge of the first panel in an orthogonal relationship.

20. The method of claim 17, comprising joining a plurality of panels of the eight or more foam panels to create a representation of a building.