FIELD OF THE INVENTION
The present disclosure relates to posable, bendable building blocks used to construct items, such as toys and/or, when used in a large scale, furniture, habitats, and other structures. Such objects are preferably made by novel insertion molding techniques and/or additive manufacturing insertion molding techniques described herein.
SUMMARY OF THE INVENTION
An exemplary posable building block system may comprise a posable component, which in a preferred embodiment may be a posable metal wire, and a plurality of rigid plastic components, which in a preferred embodiment may be only two such rigid plastic components, whereby the plurality of rigid plastic components may be coupled to one another by embedding the ends of the posable metal wire within their material thickness so as to separate each of the plurality of rigid plastic components from one another by an exposed portion of the posable component. In one aspect of this exemplary embodiment, a first rigid plastic component embeds a first end of the posable metal wire, a second rigid plastic component embeds the opposite end of the posable metal wire, and the first rigid plastic component and the second rigid plastic component are separated from one another by an unembedded length of the posable metal wire.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, at least one third rigid plastic component is disposed between the first rigid plastic component and the second rigid plastic component. In a yet further aspect, the at least one third rigid plastic component is slidable along the posable component.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, each of the first, second, and/or third rigid plastic components may be substantially the same as one or more of (i) a pre-existing interconnecting building block toy known to those skilled in the art; (ii) a pre-existing action figure, sculpture, or other three-dimensional work known to those skilled in the art; and (iii) a modification to any and all interconnecting building block toys and action figures, sculptures, and/or other three-dimensional works known to those skilled in the art, whether in existence or made in the future.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, a posable building block system may comprise a posable component that is fixedly attached to a rigid plastic component via a surface contour in the posable component. An exemplary surface contour may be the product of mechanical or manual deformations in the posable component prior to introduction into the molding cavity and/or during the manufacturing process.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, a posable building block system may comprise a plurality of components that can interconnect to the surfaces of one another while each is individually connected via a posable component. According to this exemplary embodiment, the components of such an exemplary posable building block system may take a first configuration and then be transformed into a second configuration all the while the components remain coupled to the posable component in either the first configuration, the second configuration, and any transitory configuration in route to either configuration.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, a posable building block system comprised of fixed and movable components may be used as a skeleton or scaffold for other connections to form different toy constructions and designs. According to this exemplary embodiment, a posable component of an exemplary posable building block system may be wound or twisted about the posable component of one or more other posable building block systems to form a combined structure. Alternatively, a posable building block system may be coupled to portions of toys or other three-dimensional objects so that the portions are supported by the posable building block system and can be interchanged and combined to form constructs such as figurines, action figures, and other three-dimensional creations. Further alternatively, a posable building block system may have fabric or other materials wrapped, adhered, or looped through or about the posable component and/or the rigid components to create further variations of toy and/or three-dimensional structure.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, a posable building block system may have a plurality of rigid components molded as one or more types of toy pieces, such as building blocks, figurine body parts, or other ornamental designs, that are interconnected by a posable component. Alternatively, certain of the rigid components may have one type of toy piece and other rigid components may have another type of toy piece. Further alternatively, a plurality of posable components may be utilized to interconnect the toy pieces in any form or variety.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, a molding method for an exemplary posable building block system may include steps to hold the posable component in place within the cavities making up the components and the path for the non-embedded parts of the posable component. One step may be to use parts of the mold to crush, pinch, or frictionally hold one or more sections of the posable component. Alternatively or additionally, the step may use a vacuum to hold the posable component to the mold. Further alternatively or additionally, the step may use magnetism, such as an electromagnet, to hold the posable component to the mold.
According to each and any of the forgoing, the posable component may be straightened and finished at its ends (e.g., by deforming them or bending them) prior to insertion into the mold to facilitate anchoring of components that will mold another material over the same during the molding process. The placement of an exemplary posable component into a mold for insertion injection molding may be accomplished via manual methods or may be accomplished using pick-and-place robotics using known pick-and-place technologies, e.g., vacuum end effectors, designed to accurately pick up and deliver the posable component to the appropriate channel in the mold adjacent to a cavity requiring rigid plastic injection.
In addition to the previously described embodiment and/or as an alternative to any other previously described exemplary embodiment, an exemplary posable bending block system method may involve use of features within the mold, such as actuated dies or other forming tools, to form and/or deflect an exemplary posable component after being placed in the mold but before injecting of the materials about which it will go.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a first embodiment of a posable building block (“PBB”).
FIG. 1B illustrates a second embodiment of a PBB. FIG. 1C illustrates an alternative view of the second embodiment of the PBB of FIG. 1B.
FIG. 2 illustrates the first embodiment of the PBB of FIG. 1A, but its teachings are applicable to any type of PBB, including those illustrated in any other figure referred to herein and/or FIGS. 1-5A, 6A-6B, 8D-E, 8H-J, 9C-D, 10A-K, 11C, and 11F illustrated and described in U.S. patent application Ser. No. 17/561,926, which illustrations and descriptions are incorporated herein by reference in their entirety.
FIGS. 2A and 3A each illustrates a first array of exemplary anchoring feature(s) for an exemplary end component of an exemplary PBB. FIGS. 2B and 3B each illustrates a second array of exemplary anchoring feature(s) for an exemplary end component of an exemplary PBB. FIGS. 2C and 3C each illustrates a third array of exemplary anchoring feature(s) for an exemplary end component of an exemplary PBB. FIG. 3D illustrates a fourth array of exemplary anchoring feature(s) for an exemplary end component of an exemplary PBB. Each such array may be used alone or in combination with one another along any part of the posable component.
FIGS. 4A-D illustrate views of one method by which an exemplary PBB may be selectively bent to create a construction using its rigid components.
FIGS. 5A and 5B each show an annotated photograph of an exemplary PBB and combination of a plurality of PBB, respectively. FIG. 5C provides an illustrative diagrammatic version of the embodiment of FIG. 5B.
FIGS. 6A-6F illustrate isometric, profile, topographic, plan, and cross-sectional views of another exemplary PBB.
FIGS. 6G-6I illustrate multiple views of another exemplary PBB.
FIGS. 6J-6M illustrate multiple views of additional exemplary PBB in a Lego® system environment.
FIGS. 7A-D illustrate numerous methods of anchoring a posable bendable component within rigid components to form the end components of numerous exemplary PBBs.
FIGS. 8A-B illustrate isometric views of exemplary insertion mold halves for cooperatively engaging one another to allow for manufacturing of an exemplary PBB.
FIGS. 9A-E illustrate profile diagrammatic views of exemplary manufacturing methodologies for making an exemplary PBB using an exemplary inventive insertion mold system, like those illustrated in FIGS. 8A-B and FIGS. 10A-B.
FIGS. 10A-B illustrate isometric views of exemplary insertion mold halves for cooperatively engaging complementary mold halves to allow for manufacturing of an exemplary construction comprised of multiple overlapping and intersecting PBBs.
FIGS. 10C-D illustrate isometric views of an exemplary construction made from the exemplary insertion mold halves illustrated in FIGS. 10A-B.
FIGS. 11A-B each illustrates an exemplary embodiment of a shell or snap-fit cover feature for interconnection with one or more components of an exemplary PBB.
FIGS. 11C illustrates an exemplary use of fabric or other non-rigid textile or other flexible material anchored to portions of an exemplary PBB.
FIGS. 12A-C each illustrates exemplary isometric illustrations of an insertion molding process using additive manufacturing techniques to create an exemplary PBB.
Unless otherwise stated, the symbols “●●●” used in the Figures denote the possibility of a greater length of posable bendable component used in the embodiment. Unless otherwise stated, the symbols “•••” used in the Figures denote the possibility of a greater length, different length, different shape/size/orientation/configuration of the rigid component used in the embodiment.
In the drawings like characters of reference indicate corresponding parts in the different figures. The drawing figures, elements and other depictions should be understood as being interchangeable, rearranged, repeated, reduced, changed in size and shape, and may be combined with related features and parts within their respective embodiments and combined and modified by features, whether or not related, in any other embodiments, in any like manner and in accordance with and in furtherance of the teachings and objectives disclosed. Thus, the features and methods that may be applied to any embodiment illustrated and/or described may be used in lieu of or in combination with the features and methods applicable to any type of PBB herein described.
DETAILED DESCRIPTION
An exemplary PBB 10 may be substantially the same as any of the linkages illustrated and disclosed in U.S. patent application Ser. No. 17/561,926, each such linkage being suitable for use as a PBB 10 and being incorporated herein by reference in its entirety. Generally, an exemplary PBB 10 may be made up of a posable component (“PC”) 1, at least two rigid end components (“EC”) 3, and optionally, at least one rigid body component (“BC”) 2, whereby every rigid BC/EC 2/3 is separated by a length of exposed PC 1. Thus, a first embodiment of PBB 10 may be ones comprised of one (1) PC 1 and two (2) EC 3 separated from one another by an exposed portion of PC 1. A second embodiment of PBB 10 may be ones comprised of one (1) PC 1, two (2) EC 3, and “n” BC 2, whereby “n”≥1 and each EC 3 and BC 2 is separated from one another by an exposed portion of PC 1 and each BC 2 is separated from any other BC 2 by an exposed portion of PC 1. A third embodiment involves groups of PBB 10 in the form of either a combination 20 or construct 30, which may comprise “n” PC 1, “n+1” EC 3, and “m” BC 2, whereby “n”≥1 and “m”≥0. In one aspect, PC 1 is preferably a posable metal wire while EC 3 and/or BC 2 are preferably made of plastic or other like rigid material. In another aspect, each EC 3 in the first, second, and third embodiments may be either toys or parts of toys known to those skilled in the art, such as Lego® blocks, action figures, dolls, and other play objects. In yet another aspect, each EC 3 and BC 2 in the second and third embodiments may be either toys or parts of toys known to those skilled in the art, such as Lego® blocks, action figures, dolls, and other play objects. In a still further aspect, one or more of each EC 3 and/or BC 2 in any embodiments in which they are present may be the same or different from any other EC 3 and/or BC 2 in the PBB 10 of which they are a part.
Exemplary Posable Bendable Blocks
Illustrations of the following disclosures relating to the external structure of the PBB 10, its combinations 20, and constructs 30 may be found in one or more of FIGS. 1A-C, 2, 2A-C, 3A-D, 4A-D, 5A-C, 6A-M, 7A-D, 9D-E, 10C-D, 11A-C, and 12A-C, the portions of which being provided as examples only and may be modified or combined in any manner.
An exemplary EC 3 may be comprised of an external face 6 that forms the free end of the PBB 10 and at least one internal face 5 that faces the internal face 5 of another EC 3 and/or the internal face 5 of an adjacent BC 2. Unlike EC 3, an exemplary BC 2 only has internal faces 5 due to its location between each EC 3 and/or between other BC 2. PC 1 intersects at least one surface of each EC 3 and, where present, at least two surfaces of each BC 2, at a junction 7. The separation between the junction 7 of every rigid component in PBB 10 is space 8. While not shown, PC 1 may intersect the external face 6 of an EC 3 and/or may be located outside of EC 3 following molding of the PBB 10. The axis that lies along the central length of PC 1 may be referred to as axis 11.
According to an exemplary first embodiment of PBB 10 comprised of only two EC 3 and a PC 1, an exemplary space 8 remains substantially the same during use of the PBB 10. According to the second embodiment of PBB 10, space 8 may become larger, i.e., a slack space 8+, smaller, i.e., a reduced space 8−, or may substantially be removed so that an EC 3 and the next most adjacent BC 2 or two adjacent BC 2 abut one another (i.e., the internal faces 5 come into direct contact), such coincidence being referred to herein as a contact 8&. The modification of space 8 to any of 8+, 8−, and/or 8& may be attributed to a feature of the second embodiment in which an exemplary BC 2 is not fixed about PC 1, but rather, remains free to rotate about the thickness and/or translate up and down the axis 11 of PC 1. In accordance with an exemplary embodiment, an exemplary space 8 may be substantially the same as the length of the portions of PC 1 found between junctions 7. Alternatively, an exemplary space 8 may comprise a combination of unequal lengths of PC 1 between an EC 3 and a BC 2 or between two BC 2, such as, for example, a larger than average section 8+ and a smaller than average section 8−. For irregularly shaped faces 5, an exemplary space 8 may be calculated by taking the volume of the space between the faces and dividing it by the average cross-sectional areas of the component(s) to which each of the faces 5 belong.
In some embodiments, an exemplary BC 2/EC 3 may have an upper surface 26a that exists in a plane that is parallel to a lower surface 26b. In another exemplary embodiment, exemplary EC 3/BC 2 may have projections 25, hollow extension surfaces 27, cavities 9, and friction enhancement 28 located on one or more of external face 6, internal face 5, upper surface 26a, and/or lower surface 26b, regardless of the EC 3/BC 2 three-dimensional shape. In a preferred embodiment, projections 25 and/or hollow extension surfaces 27 may be substantially the same as that of the Lego® stud and/or hollow stud, respectively, and like toy features known to those skilled in the art. In another preferred embodiment, cavities 9 may be substantially the same as the snap-fit cavities found in Lego® blocks that are designed to friction fit and interconnect with studs of another Lego® compatible block (e.g., studs such as projections 25 and/or hollow extension surfaces 27). In yet another preferred embodiment, friction enhancer 28 may be any stand-alone surfaces used in a Lego® connection cavity 9 to enhance the friction fit with adjacent studs (e.g., studs such as projections 25 and/or hollow extension surfaces 27). When a friction enhancer is also merged into one of the walls of the Lego®-like brick component 2/3, that friction enhancer may be characterized as a merged enhancer 28b, which may utilize one or more surfaces in the walls encompassing cavity 9 to enhance the friction between the cavity 9 of component 2/3 and a stud 25/27 of another interconnecting building block.
In all embodiments, an exemplary PC 1 may be any type of bendable wire that can be bent with a minimal amount of force while still being capable of maintaining the last position it was in after being bent, e.g., it can hold its bent position against the forces of gravity. In an exemplary embodiment, any object may qualify as a PC 1 as long as it can be posed and hold the last position into which it was placed. In one embodiment, PC 1 may be a metal wire made up of any type of material (e.g., steel, aluminum, bronze, copper) and comprise any type of cross-section (e.g., round, half-round, square). In a preferred embodiment, an exemplary PC 1 may be an ASTM 430 dead soft stainless steel wire made and sold by the Malin Company of Cleveland, Ohio with a full round diameter of 0.0509 in (1.29 mm). Where PBB 10 may be used as or with a toy, the diameter of its PC 1 is critical in order for the PBB 10 to pass the sharp points test under applicable toy testing standards, i.e., it must have diameters greater than about 0.045 inches.
An exemplary PC 1 may be electrically conductive, magnetic, non-conductive, non-magnetic or combinations of the same to enhance uses of PBB 10. In an another exemplary PBB, portions of PC 1 that are not embedded in a BC 2 or an EC 3 may be exposed so as to be in contact with the fingers of a user and/or may be coated with flexible material, such as a rubber or silicone. It is preferred that any such coating does not restrict or impede the ability of PC 1, BC 2, and/or EC 3 to achieve a desired conformation. In other words, according to this preferred embodiment, if PC 1, BC 2, and/or EC 3 would achieve a substantially different conformation in the absence of PC 1 coating, then the coating thickness may be too thick.
Any or all of exemplary EC 3 and/or exemplary BC(s) 2 may be made of one or more of the following moldable materials, including, but not limited to, PMMA, ABS, PA, PETG, PS, PC, PP, PE, PEEK, PET, PLA, cyanate esters, epoxies, polyesters, polyurethanes, silicones, rubbers, vulcanized rubbers, aluminum, bronze, steel, alloys, and combinations of any one of the same (e.g., a PC-ABS composition). Additionally, any of the aforementioned materials may be in any color known to those skilled in the art and include their translucent, transparent, clear, and combined versions of the same. In an exemplary embodiment, the material used in BC 2 and/or EC 3 may be optically clear and/or capable of glowing in the dark, changing color in response to one or more of heat, pressure, liquid, or other chemical interactions. In a preferred embodiment, each BC 2 and EC 3 is a rigid component of PBB 10, preferably made of PC-ABS. Alternatively, each BC 2 and EC 3 may be made out of a recyclable plastic material.
An exemplary BC 2 and/or EC 3 may be cylindrical in shape or have any other circular or rounded cross-section, polygonal cross-section, e.g., any cross-section with a shape having n+3 sides (where n is an integer≥0), or combinations of the same. Further, any of EC 3 and/or BC 2 may be spherical, polyhedron, prismatic triangular shape, pyramidal, trapezoidal, conical, frustoconical, truncated pyramidal, and/or combinations of the same, with or without additional fillets and/or chamfers on one or more surfaces or edges. Alternatively, EC 3 and/or BC 2 may possess any number and combination of potential surface contours: threading for screw-like attachments, circular bumps, longitudinal ridges, finned sections, hooks, tabs, snap-fit extensions (either indentation or the hooks themselves), hoops, and holes (either partially into the thickness of the component or a through-hole). Additionally, EC 3 and/or BC 2 may be amorphous forms shaped for particular needs as are disclosed herein, such as, for example, any part or part(s) of an action figure in whole or in part provided that the action figure part does not inhibit the posability of the exposed parts of the exemplary PC 1. EC 3 and BC 2 used in such ways for action figures is disclosed in U.S. patent application Ser. No. 17/561,926, which is incorporated herein by reference in its entirety. Furthermore, while faces 5/6 may be illustrated as substantially flat, exemplary faces 5/6 may be any shape or shapes in combination and/or may have contours and surfaces that are not flat and/or may be irregular.
In an exemplary embodiment, BC 2 and/or EC 3 may have three-dimensional shapes, such as the shape and dimensions of building blocks known to those skilled in the art, such as, for example, Lego® blocks or bricks and their variants, K'nex, PicassoTiles®, Duplo®, Rasti blocks, Flexo, Brix Construx, and magnetic building blocks. According to this alternative, BC 2 and/or EC 3 may take the form of any existing Lego® brick or variants of the same. Further alternatively, EC 3 may be one size and type of shape or building block and BC 2 another size and type of shape or building block, such as, for example, a Lego® brick EC 3 followed by a K'nex part as a BC 2 of the PBB 10. Alternatively, each EC 3 may be a different type of building block shape and/or type. Accordingly, BC 2 and EC 3 may be one or more of the foregoing sizes, shapes, and brick types and geometries to enable PBB 10 to be combined and/or used with any building block known to those skilled in the art and/or other type of toy, whether or not a building block. For example, EC 3 may be shaped to be held by an action figure while a first BC 2 may be shaped to connect with a Lego® block, a second BC 2 may be shaped to connect to a Flexo block set, a third BC 2 may be shaped to hold a pencil used for writing, and the opposing EC 3 may be designed as a plastic insert shaped to fit within a power port for a smart phone or other electronic device (e.g., USB or USB-C) or another port found on similar devices (e.g., audio jacks, HDMI ports, ethernet ports, telephone ports, coax cable ports, and/or wall outlets).
In an exemplary embodiment, the cross-section of BC 2 and/or EC 3 may be such to allow it to friction-fit within an opening in a building block known to those skilled in the art, such as, for example, the circular hole of a Lego® Erling brick (Lego® Design ID Nos. 4070, 4070a, 30069, and 35388) and/or the circular hole of an exemplary Lego® technic brick (Lego® Design ID Nos. 6541, 3700). According to the aforementioned exemplary embodiment, the diameters of such openings in such building blocks are approximately 3.2 mm to approximately 4.8 mm, which would mean the maximum thickness of BC 2 and/or EC 3 may be approximately 3.2 mm to approximately 4.8 mm in diameter and/or the maximum cavity 9 or hollow extension surface 27 may be approximately 3.2 mm to approximately 4.8 mm in length.
By shifting one or more BC 2 of an exemplary PBB 10 around and about the PC 1 through creation of slack spaces 8+, reduced spaces 8−, and contacts 8&, such as in FIGS. 4A-C, an exemplary PBB 10 may thereafter be further manipulated to form constructions from its own constituents and/or enable a wide variety of constructions not otherwise achievable with other building blocks. As may be understood from FIGS. 4A-D, properly shaped BC 2 and/or EC 3 may be used to create transforming building blocks, figures, structures, and/or toys due to the unique ability to fold into and around one another while staying together about the PC 1 to which they are coupled. According to these exemplary embodiments, such exemplary PBBs 10 may provide new ways to build transforming toys without the associated need for separate moving parts required such as gears, screws, and separate joining mechanisms. Alternatively and/or additionally, the transforming effect previously described may also be used for building blocks. Thus, a car or truck built of a building block, e.g., Lego® blocks, may be built of one or more PBBs 10 such that they can be folded and unfolded to reveal an alternative toy comprised of the BC 2 and EC 3 used therein, e.g., a robot or figure. Thus, an exemplary PBB 10 having BC 2 and EC 3 shaped as different parts of figurines or robots can also be capable of transforming from one shape to another through twisting, turning, and shuffling of its constituent components BC/EC 2/3 via creation of spaces 8, 8+, and 8−, and contacts 8&. Depending on the type of BC 2 involved, a contact 8& may be the surface contact between faces 5 or it may involve friction-fit and/or interlocking arrangements between features in faces 5 (e.g., snap-fit, hook, ball-socket, plug, Lego®-like stud-and-cavity connection). Accordingly, a user of an exemplary PBB 10 may “build” structures out of its components by making contacts 8& along the length of PC 1 and constructing from one or more BC 2 and/or EC 3 of the same PBB 10 or a different PBB 10.
In an exemplary transformation process illustrated by FIGS. 4A-D, an exemplary PBB 10 may have its EC 3(a)-(b) and BC 2(a)-(c) moved either around and/or along axis 11 of an exemplary PC 1 according to the white arrows illustrated. According to FIGS. 4A-B, BC 2(a) and 2(b) may each be rotated 180° about axis 11 of PC 1 while BC 2(a) may be brought closer to EC 3(a) and BC 2(b) may be brought closer to BC 2(c) or stay at the same distance. An exemplary BC 2(c) may be moved closer to EC 3(b). During this process, in particular at the point in time during which the configuration illustrated in FIG. 4C results, an exemplary end component 3(a) and BC 2(a) may form a component coupling 24 while a slack space 8+ forms between BC 2(a) and BC 2(b). According to this exemplary embodiment, the space 8 between BC 2(b) and BC 2(c) may remain so long as a sufficient amount of PC 1 exists to accomplish the construction step. Further according to this exemplary embodiment, the prior space 8 between BC 2(c) and EC 3(b) may be shortened to become reduced length 8−. FIG. 4C may also provide for folding steps Δ1, Δ2, and Δ3, which by way of the arrowhead direct the folding of body components 2(a)-(c) and folding of EC 3(b) using the posability of the PC 1. Thus, according to step Δ1, BC 2(b) may be flipped on top of the underside 26b of BC 2(a). According to step Δ2, BC 2(c) may be flipped on top of the extensions 25 of BC 2(b) while EC 3(b) is not yet stabilized in place. Finally, according to step Δ3, the exemplary end component 3(b) may be bent at a substantially right angle so that a narrow space in its connection cavity 9 opposite its extensions 25 may be used to cover any excess PC 1 and keep it out of sight. For the sake of clarity, an otherwise exposed PC 1 does not become an embedded portion le merely because it is kept out of sight unless in the process of being kept out of sight it is simultaneously embedded within a BC/EC 2/3. Depending on the shape and contour of a particular BC 2 and/or EC 3, an exemplary PBB 10 may be capable of being bent, rotated, and/or folded in such a way to form numerous contacts 8& between its constituent components 2/3 and in the process “hide” the exposed PC 1 and/or cause it to be “tucked” out of view of the resulting combiner BC 22 using a cavity 9.
FIG. 4D may provide an illustrative embodiment of a novel construction that may be formed from the conversion process discussed with respect to FIGS. 4B-C. An exemplary construction made up of PBB 10 may be propped up by EC 3(a) and 3(b) while the extensions 25 of BC 2(a) face the support surface for the EC 3(a)-(b). According to this illustrative embodiment, BC 2(b) and 2(c) may be snap-fit with one another while EC 3(b) may be folded down so that a cavity 9 opposite the side of EC 3(b) bearing the extensions 25 may conceal the portions of PC 1 that were used to fold BC 2(b) on top of BC 2(a). As is shown via transparency, each section of PC 1 embedded in a BC 2(a)-(c) and an EC 3(a)-(b) is an embedded portion le. However, as shown in the ovular dashed-line call-out nearest to EC 3(b), the PC 1 that is concealed by EC 3(b) is not an embedded portion le, but would be exposed but for the cavity 9 into which it may be snuggly fit. Where the EC 3(a)-(b) and BC 2(a)-(c) are not building blocks, but elements of a vehicle or another structure, the PBB 10 to which they are affixed may allow for the vehicle or structure to take two or more forms just by twisting and manipulating the PC 1 to which all the EC 3(a)-(b) and BC 2(a)-(b) attach.
With reference to the illustrative PBB 10 shown in FIGS. 5A-C, an exemplary slack space 8+ may be the result of translating BC 2 components away from one another or away from an EC 3. FIG. 5A illustrates a PBB 10 that is a type of physical embodiment of one or more of the illustrative embodiments shown and described with respect to FIGS. 1A, 2, and 2A-C. An advantage of an exemplary slack space 8+ may be to allow for conformations in PBB 10 that may not otherwise be possible if BC 2 remained at spaces 8 from one another and/or EC 3, such as wrapping an exemplary PBB 10 about an object or permitting a twist It with another PBB 10, as illustrated in FIGS. 5B-C. Additionally, slack space 8+ may be reduced in size to an exemplary space 8 after a desired conformation of PBB 10 is achieved. Another benefit for slack space 8+ may be to allow sharp turns and twists in the PBB 10 that may not otherwise be permitted when a space 8 is in existence. Thus, by virtue of the ability of BC 2 to freely translate about PC 1, an exemplary PBB 10 may be able to shift BC 2 to enable it to increase the number of different conformations achievable in a space. In one aspect, BC 2 may be moved along the PC 1 by translation, twisting, revolving, or other means of moving known to those skilled in the art depending on the particular PC 1. For example, where PC 1 is a smooth and anodized annealed wire, an exemplary BC 2 may slide along the length of the posable wire. As another example, where PC 1 may be a formation of different materials interwoven together, e.g., an exemplary posable interwoven PC 1i, then an exemplary BC 2 may be turned like a screw to go up and down the length of posable interwoven component 1i. In an exemplary embodiment, the material of BC 2 and the material of PC 1 may be such that there is sufficient friction between the two to allow the component BC 2 to be controllably shifted and/or the BC 2 to be able to retain its shifted position either obtained by translation about or rotation around the length of the PC 1.
According to the illustrative embodiments of FIGS. 5B-C, a single exemplary PBB 10A may be a scaffold for connecting numerous other exemplary PBB 10, such as, for example, illustrated PBB 10B, to form a combination 20. According to another exemplary embodiment, PC 1 belonging to PBB 10B may be connected to PBB 10A via a twist It about the PC 1 of PBB 10A. Accordingly, each of PBB 10A and PBB 10B may be stably held in place between the faces 5 of each BC 2 and/or EC 3 within the locus of twist 1t. The tightness of the twist It may dictate the rigidity between the PBB 10A and PBB 10B to allow each to stably maintain each of their bent configurations in space. Alternatively, the friction between BC/EC 2/3 implicated in any twist It may enhance the rigidity between PBBs 10A and 10B. For example, exemplary BC/EC 2/3 may form snap-fit arrangements whenever engaged in or part of a twist 1t. Moreover, a plurality of PBB 10A/10B may be coupled as previously described and as illustrated, to form an exemplary combination 20.
In summary, an exemplary PC 1 may be any length and cross-section of a posable bendable material, such as a metal wire, and each EC 3, as well as any BC 2 when present, may each be any size and shape capable of being coupled to the surface of a PC 1 without being removable from the same and may be made from any type of relatively rigid material, such as a plastic, e.g., BC 2 and EC 3 may each be any type of known toy type or portion of such known toy type, any type of product or portion of known product type, and/or combinations of the same meant to combine with any other compatible toy or product known to those skilled in the art.
Exemplary External and Internal Structures of Exemplary Posable Bendable Blocks
Illustrations of the following disclosures relating to the internal structure of the PBB 10, its combinations 20, and constructs 30 may be found in one or more of FIGS. 1A-C, 2, 2A-C, 3A-D, 4A-D, 5A-C, 6A-M, 7A-D, 9D-E, 10C-D, 11A-C, and 12A-C, the portions of which being provided as examples only and may be modified or combined in any manner.
An exemplary PC 1 of an exemplary PBB 10, combination 20, and/or construct 30 may have numerous portions that may be characterized in terms of their function, location, and formation among and within the more rigid EC 3 and/or BC 2. Every exemplary PC 1 may have at least one end point or terminus 1z that is separated from another end point or terminus 1z by a bendable and posable length. In an exemplary embodiment, each terminus 1z may be completely embedded in an EC 3, although it may be visible at the external face 6 of the EC 3 or via an opening 4 through a thickness of the EC 3, which may also be the cavity 9 bounded by lower surface 26b. In all embodiments, the portions of PC 1 that are substantially surrounded by the material making up EC 3 and/or BC 2 may be considered embedded portions 1c. As previously discussed, while the portions le may never change in the first embodiment, these portions 1e may shift and change during use of a PBB 10 configured according to the second embodiment due to the ability of a user to move the BC 2 about the PC 1 to create slack spaces 8+, reduced spaces 8−, and contacts 8&. In an exemplary embodiment, the length of PC 1 found between free face 6 and internal face 5 of an exemplary EC 3, i.e., the length having the terminus 1z, may be referred to herein as the “terminal region.”
In all embodiments, an exemplary PBB 10 and/or construct 30 require PC 1 to be anchored so that its rigid elements (EC 3 and/or BC 2) do not allow the PC 1 to break free of the rigid elements during normal use. Therefore, an exemplary PC 1 may be anchored to EC 3 at or near the terminal region, although one may anchor one or more BC 2 at points along PC 1. To anchor an exemplary PC 1 to a rigid component, whether an exemplary EC 3 or an exemplary BC 2, PC 1 may utilize one or more features and combinations of features illustrated in FIGS. 2A-C, 3A-D, 6F-M, 7A-D, 9A-E, 10D, and 12A-C or features and combinations of features illustrated or described in U.S. patent application Ser. No. 17/561,926, each of which being incorporated herein by reference in their entirety: (i) a bent portion 1b (as shown in FIGS. 1, 2A-B, and 3B of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (ii) a crushed portion 1c having one or more crushed sections 1* (as shown in FIGS. 1, 2A-E, 3A-B, and 3D-E of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (iii) a deformed portion 1d with one or more deformations 1x and/or extensions 1w (as shown in FIGS. 1, 2D-G, and 3C-E of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (iv) a residual portion 1r (as shown in FIGS. 2A-E, 3A-B, and 3D-E of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (v) an orifice 1o (as shown in FIGS. 2H-I. an 3F of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (vi) a twist 1t (as shown in FIGS. 2H-I and 3F of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); (vii) an underside 1u (as shown in FIGS. 2A-B, 2E, 3A-B, and 3D of U.S. patent application Ser. No. 17/561,926 and otherwise described therein); and (viii) combinations, patterns (including random and non-random patterns), and angular conformations of each of (i)-(vii) along the length of each EC 3 and/or BC 2, such as the angle 13 of bend 1b from axis 11 and the combination with residual portions 1r and crushed surface 1* and underside 1u in FIG. 3B (or as shown in FIGS. 2A-B, 2D-E and 3D-E of U.S. patent application Ser. No. 17/561,926 and otherwise described therein). Furthermore, while a straight portion 1s may also be employed in an exemplary PC 1 (as shown in FIGS. 2C-G, 3A, and 3C-D of U.S. patent application Ser. No. 17/561,926 and otherwise described therein), such straight portions 1s may not adequately anchor an exemplary PC 1 without sufficient roughening of its surface or other treatments to allow the material of an exemplary EC 3 and/or BC 2 to maintain it within its thickness during normal use and/or operation. In a preferred embodiment, an exemplary BC 2 may not have any of the foregoing structures on the embedded length 1e found between its faces 5 thereby enabling an exemplary BC 2 to displace, e.g., slide, along axis 11 of the PC 1.
An exemplary PC 1 may comprise one or more deviations from the central axis 11 (1b/1o/1t), deformations (1c/1d/1r/1u/1x/1*) that create discontinuities or changes in PC 1 thickness, straightness, or shape, and/or combinations of one or more of the same that would enable anchoring of PC 1 within a rigid material, such as the type used in EC 3 and/or BC 2, and prevent it from being removed from the exemplary EC 3 and/or BC 2 during normal use and/or operation of PBB 10, combination 20, and/or construct 30. As may be illustrated in FIGS. 3A-3D, certain features may yield additional material space $ within the rigid component, such as EC 3, due to their simplicity, like deformed portion 1d, or due to their multifaceted locations for rigid material fixation, like helix wire 1i. In certain embodiments, the deformation 1x may be the result of a pre-insertion deformation process (e.g., deformations 1x being formed outside of the PBB 10 mold) while in other embodiments, the deformations, e.g., 1c, and/or deflections, e.g., bend 1b, may be the result of a formation process using dies and other mechanisms to be discussed that operates on the PC 1 after being inserted into the injection mold cavity(ies). According to an exemplary embodiment, the increased variety, number, and dimension of each of the foregoing features may increase the anchoring between PC 1 and EC 3, and, where applicable, between PC 1 and BC 2.
Where an exemplary PC 1 comprises a helix of two components, as illustrated in FIG. 3D, it may be possible to weave two different materials together, e.g., a posable interwoven PC 1i may be a twisted helix of one magnetic wire of one gauge and another wire that is not magnetic. In yet another aspect, the posable interwoven PC 1i may be composed of a plurality of metal wire constituents and/or non-metal components, such as, for example, a yarn, string, or fabric constituent, a dissolvable constituent, such as a poly-vinyl alcohol (PVA) yarn, string, tape, or thread, a low-melting point constituent, or combinations of the same. According to this exemplary type of hybrid posable interwoven PC 1i, an exemplary fabric constituent may allow material being over-molded onto the posable interwoven PC 1i to embed itself into the pores of the fabric and thereby hold to the fabric and metal wire constituents simultaneously. According to another exemplary embodiment of a hybrid posable interwoven PC 1i, an exemplary dissolvable constituent may be dissolved in response to material engaging the rest of posable interwoven PC 1i during the PBB 10 forming process and, in dissolving, provide gaps or voids lo within the posable interwoven PC 1i helix to allow material making up the PBB 10 components to flow through and/or adhere (e.g., see orifice lo illustrated in FIG. 3D and illustrated and described with respect to FIGS. 2H-I and FIG. 3F of U.S. patent application Ser. No. 17/561,926).
The locations of the deviations and deformations in PC 1 may be governed by the amount of material available in the EC 3 and/or BC 2. An exemplary deformation 1d having a deformed portion 1x or a bent portion 1b may be located under a projection 25 and/or hollow extension 27 in an exemplary EC 3 as illustrated in FIGS. 6F and FIGS. 7A-D. Where FIGS. 6F and FIGS. 7A-B may illustrate a cross-sectional view of an embodiment involving EC 3 shaped in the form of a Lego® compatible block, an optimal anchoring point may be in the area 3x under the stud 25/27 of Lego®-like block EC 3. The area under the stud (“AUS”) 3x may be optimal as the majority of material for the EC 3 may be found here and may firmly embed the terminal region of PC 1 therein. Preferably, PC 1 may be located at a distance above lower surface 26b and under upper surface 26a that allows PC 1 to interconnect the EC 3 but not interfere with structures below it that may be found in space 8, e.g., the studs 25 of adjacent Lego® blocks 55 as shown in FIGS. 6J and 6L. Using FIGS. 6F, 6J, 6L and FIGS. 7A-B as examples, coupling either EC 3(a) or EC 3(b) of PBB 10 via connection channel 9 may result in a stud 25 being located within space 8. Thus, if axis 11 of PC 1 were such that PC 1 would be located too close to surface 26b, e.g., approximately half the PC 1 thickness away from the upper-most surface of cavity 9, then PC 1 would interfere with the stud in space 8. Therefore, it is contemplated that axis 11 of PC 1 be located sufficiently above lower surface 26b, so as to allow the EC 3(a) and 3(b) to interact with other Lego® parts without interfering with adjacent structures, e.g., other studs 25 of adjacent blocks 55. In a preferred embodiment, an exemplary clearance position 29 (e.g., lowest-most extent of support 25z holding PC 1) may be located at least about 1.6 mm to 1.8 mm away from lower surface 26b to avoid contact with studs that may be found in space 8, as may be illustrated by FIG. 6L. While FIG. 6F may show AUS 3x to be most adjacent to the interior faces 5 of each EC 3(a) and 3(b), it may be that one or both of the EC 3(a)/3(b) may have the anchoring AUS 3x at a position nearest external face 6, as may be illustratively shown in FIG. 7A.
Further alternatively, while AUS 3x may be optimal as described and as shown in FIG. 7A, a sufficient anchoring of PC 1 within an exemplary EC 3(a) may be accomplished without the need for locating PC 1 below any projection 25, as may be shown in FIG. 7B. FIGS. 7A-B may provide one or more types of PC 1 anchoring in exemplary EC 3 that is in the form of a Lego® block that is greater than 3.2 mm in height or 8 Lego Draw Units (“LDU”). Thus, the anchoring teachings of FIGS. 7A-B in which sufficient AUS 3x is maintained may be used to couple any type of Lego® brick and any type of Lego® block that is the equivalent of at least two plates thickness. Where AUS 3x may not exist, a properly configured bend 1b (as shown in FIG. 7C) or bend and deformation combination (as shown in FIG. 7D) may be used to anchor PC 1 to an exemplary Lego® block shaped EC 3(a)/3(b) so that it may be located at the proper stud 25 clearance position between upper surface 26a and lower surface 26b. Thus, the anchoring features and placements disclosed herein may be utilized to couple any Lego® block-type EC 3 to any other Lego® block-type EC 3 and/or BC 2. With a properly sized PC 1 and properly configured terminal region of such PC 1, any PBB 10 based on these disclosures may be capable of integration into the Lego® system. An exemplary deformed region 1d or crushed region 1c may be sufficiently thin and shaped to fit within an appropriate thickness between surfaces 26a and 26b of Lego® block shaped EC 3 to couple the same to another EC 3 and/or BC 2, regardless of whether that other EC 3 and/or BC 2 is also a Lego® block shaped component of PBB 10.
It may be that a modified version of a Lego® block may be made to form an EC 3 that can be coupled via PC 1 and be seamlessly integrated into the Lego® system. An exemplary PBB 10 based on a modified Lego® block design may be illustrated in FIGS. 6G-M. As illustrated in FIG. 6G, an exemplary PC 1 may be anchored within a combination of a standard Lego® brick and integrally molded support 25z that extends outwardly from a wall formed between a block extension 26c and either upper surface 26a and/or lower surface 26b. Due to certain modifications, cavity An exemplary support 25z may extend along the same axis 11 of PC 1. Support 25z may provide sufficient AUS 3x to allow for proper anchoring of PC 1 to EC 3(a) and 3(b) while also positioning PC 1 sufficiently above where any stud 25 may be located within space 8. According to the illustrative embodiment in FIGS. 6H, 6J, and 6L, a buffer feature 25f may be utilized to ensure the lower-most extent of support 25z has sufficient clearance 29 so as not to interfere with any other structures, e.g., studs 25 of adjacent blocks 55, found in space 8. Thus, an exemplary PBB 10 designed according to embodiments like those illustratively provided for in FIGS. 6G-M may be comprised of a Lego® compatible modified block-shaped EC 3(a)/3(b) sufficiently interconnected by PC 1 and ready to be seamlessly incorporated into the Lego® system, such as block 55. In a preferred embodiment, an exemplary EC 3(a)/3(b) according to FIGS. 6G-M may have PC 1 located approximately 3.2 mm from lower surface 26b and be configured so that the difference between extension 26c and upper surface 26a is approximately 1.6 mm to 1.8 mm, e.g., the height of projection 25 (which may also be interchangeable with hollow extension 27 as illustrated in FIGS. 6J and 6M). Further preferably, exemplary support 25z may be approximately 3.2 mm in diameter and extend a distance of approximately 0.8 mm to 3.2 mm, e.g., 50% to 200% of the height of projection 25. According to one such aspect, an exemplary support 25z may extend along the axis 11 of PC 1 sufficiently to receive further interconnections with other Lego® blocks or appropriately shaped rubber gaskets or corrugated plastic tubes. With respect to appropriately shaped rubber gaskets or corrugated plastic tubes, such items may be substantially cylindrical with at least one longitudinal slit or opening that enables the gasket or tube to flexibly go about a circumference of an exemplary cylindrical-type support 25z and snap about the same so that the substantially uncut portions of the gasket and/or tube cover the exposed portions of PC 1 like a tunnel structure between the EC 3 and/or BC 2 between which it extends.
Consequently, the above-mentioned preferred features optimize the amount of PC 1 available for multivarious posabilities between EC 3(a) and EC 3(b) components, but also provide an additional use of support 25z as another type of cylindrical surface for Lego® clip-type connections and/or mini-figure gripping. Furthermore, while the extension 26c and support 25z combination may be located on a one stud (projection 25) Lego®-like block EC 3, it may be understood that any number and combinations of portions of the EC 3 may be modified into any Lego® block known to those skilled in the art, such as, for example, a Lego® block comprising at least two studs (projections 25/27) located on the same axis 11 as PC 1, a Lego® block comprising at least two studs (projections 25/27) separated from one another by the axis 11 of PC 1, a Lego® block without studs (projections 25/27) on its upper surface 26a, and combinations of the same. Examples of such alternatives may be illustrated using FIGS. 6J-M.
In another exemplary embodiment, EC 3(a) and EC 3(b) of FIGS. 6J-K may have a cylindrical cross-section that allows the particular PBB 10 to rotate atop other Lego® blocks 55 so that it permits even greater degrees of posability of PC 1 when located adjacent a wall of another Lego® block, such as, for example, rotation of EC 3(c) up to clearance position 29 in FIGS. 6J-K. In another alternative embodiment, as may be illustrated by FIG. 6J, the extensions 26c may be either the same length as one side of the Lego®-like block, e.g., EC 3(a), EC 3(b), or the extension 26c may be only a portion of the length of the side of the Lego®-like block, e.g., EC 3(d). Where extension 26c may be used for anchoring an exemplary PC 1, it may have a corresponding portion of lower surface 26b found in the same plane as it as well as any other friction enhancers either integral with the lower surface 26b (e.g., a merged friction enhancer 28b) and/or isolated friction enhancers (e.g., independent friction enhancer 28).
Exemplary Manufacture Methods of Exemplary Posable Building Blocks
All methods of making any of the aforementioned features in PC 1 may be found in U.S. patent application Ser. No. 17/561,926, the disclosures of which are incorporated herein by reference in their entirety, specifically, all embodiments and disclosures related to FIGS. 7A-E, 8A-J, and 9A-H in U.S. patent application Ser. No. 17/561,926.
The exemplary PBB 10, 10A, and 10B illustrated and/or described in any disclosed, illustrated, and interrelated and/or interchangeable embodiments may be made from plastic injection insertion molding of the embedded PC 1 (or other like processes known to those skilled in the art, such as for example, ABS injection molding) as may be illustrated in FIGS. 9A-E or by embedding the PC 1 during additive manufacturing, as may be shown in FIGS. 12A-C. Exemplary injection molding processes may use horizontal or vertical presses, but preferably vertical presses with rotary tables for the molds (which may be illustratively provided for in FIGS. 8A-B and 10A-B). Any machinable or moldable materials and methods known to those skilled in the art may be used to fabricate the molds and components disclosed herein, such as aluminums, steels, or particular polymers and elastomers. To the extent an element of an injection mold illustrated or described with respect to FIGS. 8A-B and 10A-B is not expressly stated for any particular embodiment or is not otherwise found in the incorporated disclosures of U.S. patent application Ser. No. 17/561,926, such as, for example, cooling channels, release contours, particular injected material passage features (e.g., cashew gates or replaceable gates), or surface treatments, those skilled in the art would understand that such element is inherent in injection molding technologies or injection molding methods and should be considered to also be present in any of the embodiments and disclosures illustrated and/or described as an alternative with respect to FIGS. 8A-B, 9A-E and 10A-B. Those skilled in the art would also understand the design and implementation of the peripheral components used in such injection molds and mechanisms to take plastic in raw form (pellets or liquid) and inject it into the mold constructs illustratively and otherwise disclosed herein. What follows are disclosures of the exemplary inventive molds for injection molding of exemplary PBB 10 and/or constructs 30.
An exemplary mold base 100 may be illustrated by FIG. 8A. An exemplary mold base 100 may comprise a working face 100a in which there may be (i) one or more orientation zones 140 to allow for orienting with adjacent mold parts; (ii) one or more alignment cavities 143-144 for use in placement of a PC 1 within the mold base 100 by automated or manual placement means; and (iii) a work zone 110 where an exemplary PBB 10 is manufactured. Opposite the working face 100a is the rear face 100b, which may have additional features to be described. An exemplary cover mold 200 may be illustrated by FIG. 8B. An exemplary cover mold 200 may comprise a working face 200a in which there may be (i) one or more orientation zones 140 to allow for orienting with adjacent mold parts and (ii) a work zone 210 where an exemplary PBB 10 is manufactured in conjunction with mold base 100. Opposite the working face 200a is the rear face 200b, which may have additional features to be described. In an exemplary embodiment, where mold base 100 is immobile in an exemplary mold press (horizontal or vertical), then mold cover 200 is mobile. According to this exemplary embodiment, an exemplary immobile mold base 100 may contain one or more features in the working zone 110 to hold PC 1 therein independently of or in conjunction with mold cover 200 during the injection molding process. In another exemplary embodiment, the aforementioned mobile and immobile roles of mold base 100 and mold cover 200 may be interchanged and/or shared with any other mold components depending on the surfaces necessary to make an exemplary PBB 10.
With reference to FIG. 8A, an exemplary working zone 110 may comprise half cavities 102 and 103 that are interconnected by channels 107 through cavity partitions 108. An exemplary half cavity 102 may have two walls 105, one adjacent to each channel 107 flowing into the half cavity 102. An exemplary half cavity 103 may have a wall 106, for which there is no channel 107, and a wall 105, which like wall 105 for half cavities 102, is adjacent a channel 107 flowing into half cavity 103. As further illustrated in FIG. 8A, a die pin 104 may extend upwardly from a surface of half cavity 103, although an exemplary half cavity 103 may not have any such die pin extending upwardly from its surface. An exemplary working zone 110 may also have a plurality of ejector pin ports 121 and passages 122 running through the thickness of mold base 100. In an exemplary embodiment, ejector pin ports 121 may only be located within either or both of half cavities 102 and/or cavities 103. In another exemplary embodiment, passages 122 may only be located in channels 107. With further reference to FIG. 8A, an exemplary mold base 100 may have an injected plastic feeding system comprised of a sprue 115 that feeds injected plastic into runners 116, that flows through branches 117 and enters one or more half cavities 102/103 by way of a gate 118. While a specific form of injected plastic feeding system may be illustrated by FIG. 8A, those skilled in the art may vary the shape and features of the sprue 115, runners 116, branches 117, and gates 118 as is known in the art to enable a complete and/or sufficient manufacture of the particularly-shaped and arranged components EC 3 and BC 2 of an exemplary PBB 10. Alternatively, an exemplary mold base 100 may have a working zone 110 that is devoid of an injected plastic feeding system runners 116, branches 117, and/or gates 118, as may be illustrated with respect to FIG. 8B.
With reference to FIG. 8B, an exemplary working zone 210 may comprise half cavities 202 and 203 that are interconnected by channels 207 through cavity partitions 208. Each half cavity 202 may have two walls 205, one adjacent to each channel 207 flowing into the half cavity 202. Each half cavity 203 may have a wall 206, for which there is no adjacent channel 207, and a wall 205, which like wall 205 for half cavities 202, is adjacent a channel 207 flowing into half cavity 203. Like the exemplary mold base 100 illustrated in FIG. 8A, a die pin 204 may be present in a surface of half cavity 203 and/or 202 of an exemplary cover mold 200 (e.g., FIG. 8B). Again, while a specific form of injected plastic feeding system may be illustrated by FIG. 8B, those skilled in the art may vary the shape and features of the sprue 115, runners 116, branches 117, and gates 118 as is known in the art to enable a complete manufacture of bendable PC 10, such as by placing runners 116, branches 117, and/or gates 118 into the working zones 110 and/or 210 of exemplary mold base 100 and/or mold cover 200 either in whole or in part. Alternatively, an exemplary mold cover 200 may have a working zone 210 that is devoid of an injected plastic feeding system runners 116, branches 117, and/or gates 118.
It is contemplated that those skilled in the art may use one or more hot runner systems to feed injected material into the cavities formed by the combination of mold base 100 and cover 200. Further, while the die pins 104/204 may be shown in a static arrangement, nothing in these disclosures so limits the die pins 104/204 to immobile operation. In other words, die pins 104/204 may be any form or variety to perform operations on a PC 1 found within the channels 107/207 of an exemplary mold base 100, mold cover 200, and the abutment of the same (e.g., contact between mold base surface 100a with mold cover surface 200a, and/or the abutment configuration shown in and described with respect to FIG. 7E of U.S. patent application Ser. No. 17/561,926, which is incorporated herein by reference in its entirety). In other words, the instant disclosures contemplate mechanized or controlled pneumatic, screw-actuated, or otherwise time/pressure/sensor-based control of dies 104/204 to cause a deflection (e.g., 1b, 1t) or a deformation (e.g., 1*, 1x, 1r, 1u, 1w) in PC 1. Those skilled in the art could vary the surface of a particular die 104/204 to vary the dimensions and configurations of any PC 1 deflection or deformation, e.g., dies 104/204 with circular cross-sections may create a circular crushed portion 1*, a circular underside 1u, and a crescent-shaped 1r on either side of the circular crush 1 *. Alternatively, a rectilinear die 204 and a concave cylindrical die 104 may only cause a rectangular dent 1x in PC 1 because the concave surface of die 104 would cup the PC 1 during the die 204 deformation process.
As illustrated in FIGS. 8A-B, gates 118 may take the form of a “Y” that may advantageously simultaneously feed two volumes separately formed from the combination of half cavities 102 and 202 and/or half cavities 103 and 203 or two volumes separately formed by the combination of two half cavities 102 and two half cavities 202. Accordingly, by placing the gates 118 adjacent to the walls 105/205 of a given half cavity 102/103/202/203, the resultant injection-molded product may be removed from the molds 100/200 and thereafter be cleaved from the plastic that had filled gates 118 without any residual plastic interfering with the outer peripheries of the components 102/103 formed thereby. In other words, positioning gates 118 to feed behind the walls 105 that will become the internal surfaces 5 of exemplary components 2/3 may allow the removal of the final PBB 10 while substantially reducing and/or eliminating the possibility of residual plastic from the manufacturing process resulting on the outermost surfaces of the components 2/3 (e.g., gates 118 that form a “Y” while also operating as submarine gates and/or gates that shear excess injected plastic during formation process). An exemplary molded result whereby the PBB 10 is still coupled to its gates 118 may be of the type identified by and described with respect to numeral 70 illustrated in FIGS. 8H-J of U.S. patent application Ser. No. 17/561,926, all of which being incorporated herein by reference in its entirety.
Furthermore, due to the need for placement of PC 1 within the channels 107/207 of the exemplary mold base 100/mold cover 200, such channels 107/207 may be configured so that flow of liquid injected material is substantially eliminated through such channels when PC 1 is found therein. To the extent any injected material makes its way into channels 107/207 during the manufacturing process, those skilled in the art may control the injected material amount, flow rate, and temperature to either avoid the result and/or allow for post-processing involving peeling away or breaking such residual material from the otherwise exposed portions of PC in the formed exemplary PBB 10.
FIGS. 9A-E illustrate an exemplary manufacturing methodology using one or more of the components, features, and embodiments described in and/or illustrated via FIGS. 8A-B and/or 10A-B. It should be understood that the mold base 100 and mold cover 200 of FIGS. 8A-B and/or 10A-B may have one or more of the features depicted in each other's drawings, may have variability in those features' size, configuration, order, orientation, and placement, and may be modified by persons skilled in the art to adequately achieve the desired shape, size, and functionality of any given BC 2, EC 3, PC 1, and overall PBB 10.
As may be further illustrated with respect to the illustrative embodiments of FIGS. 9A-E, an exemplary passage 122 may be the conduit for other components and mechanisms for use in manufacturing an exemplary PBB 10, such as: (i) vacuum/suction VAC; or (ii) magnetic mechanisms M (either permanent or controllable/electromagnet). Additionally, as may be found with reference to the closing step between mold parts 100 and 200 illustrated in FIGS. 9B-C, exemplary channels 107/207 may retain an exemplary PC 1 within one of its contours using one or more of the following: (i) a pressure contour in channel 207 to frictionally hold a cross-section of the PC 1 against the opposing mold channel surface; (ii) a vacuum/suction VAC that creates suction through passage 122 that holds the surface of the PC 1 into the channel 107/207; or (iii) a magnetic source (either permanent or controllable/electromagnet) M that resides within passage 122 that attracts an appropriately magnetized PC 1 into channel 107/207.
With reference to FIG. 9A, an exemplary loading step 801 may be illustrated. According to an exemplary embodiment, a PC 1 having two pre-formed deformations 1x found in deformed portions 1d proximal to the respective terminus 1z at each end of PC 1 may be disposed above the locations in mold base 100 where it is to be located. This may be done via automated or manual means. Exemplary manual loading steps 801 may include using a trained operator or a team of operators to place the PC 1 within mold base 100 along an assembly line and/or rolling the PC 1 along surface 100a until it falls into the proper channel 107. In an exemplary rolling loading step 801, an exemplary PC 1 may be rolled along one or more barriers with protrusions designed to fit within one or more of the alignment grooves 143 in mold surface 100a. Alternatively, an exemplary automated loading step 801 may involve each PC 1 being picked up or lifted and placed into channel 107 using robotic arms of two or more degrees of freedom (such as, for example, a Mecademic Meca500 6-axis robot arm, made by Mecademic Robotics, Montreal, Canada), automated vacuum loading systems with end effectors that utilize one or more of magnets, tweezers, or vacuum-assisted tweezers, such as the ESD-Safe Tweezer-Vac™ Continuous Vacuum System with Pick-Up Tool that is manufactured and sold by Virtual Industries, Inc. of Colorado Springs, Colorado or one or more of the vacuum pick-ups manufactured and sold by EIS Inc. of Atlanta, Georgia. Alternatively, a person of ordinary skill in the art would understand how to devise single or multi-cavity vacuum end effector to serve as the end effector of an exemplary pick-and-place robot known to those skilled in the art.
According to another aspect of the exemplary embodiment illustrated by FIG. 9A, PC 1 may be a specifically configured PC 1 so as to be in alignment with one or more of the channels 107 in mold base 100 when disposed therein. In a preferred embodiment, specifically configured PC 1 may take the form of a straightened and cut wire, such as a wire between 30 AWG and 14 AWG, and preferably, 16 AWG and/or 1.29 mm (0.0509 in.) outer diameter that has been straightened, cut to length, and/or otherwise treated by wire straightening and cutting machines and mechanisms, such as those made and sold by Novo Precision of Bristol, Connecticut. Referring still to FIG. 9A, an exemplary PC 1 may have deformations 1x that may face away from cavities 102/103, but they may alternatively face in any circumferential direction about PC 1 axis 11 when loaded within mold base 100. As may be further illustrated in FIG. 9A, PC 1 in an exemplary loading step 801 may be brought into mold base 100 via magnetic attraction to magnetic source M or be brought into mold base 100 via a suction or vacuum source VAC. According to this exemplary embodiment, use of magnetic source M and/or vacuum source VAC may cause PC 1 to be disposed within channels 107 in mold base 100 and remain in place while the rest of the manufacturing process continues. While not shown, those skilled in the art would readily appreciate a variety of ways to control magnetic source M as an electromagnet through mold base 100's thickness. Alternatively, magnetic source M may be a permanent magnet that is affixed within mold base 100. While not shown, those skilled in the art would readily appreciate a variety of ways to control vacuum source VAC by use of hoses or other vacuum tubing and arrangements behind mold base 100. Again, while magnetic source M and vacuum source VAC may be illustrated in an exemplary mold base 100, they may similarly be found in an exemplary mold cover 200, depending on needs.
With reference to FIG. 9B, an exemplary approach step 802 may be illustrated showing the PC 1 loaded within mold base 100 according to loading step 801 but now ready for advancement of mold cover 200. As shown in FIG. 9B, the loading step 801 that is illustrated in FIG. 9A may be complete once PC 1 is nested within channels 107 of mold base 100. Alternatively, the loading step 801 may be complete once PC 1 is sufficiently stabilized atop one or more surfaces in mold base 100, which may include channels 107, cavities 102/103, magnets M, and/or upper surface of die pin 104. As previously described, in any or all of the aforementioned completed loading steps 801, magnetic source M and/or vacuum source VAC may still be on and/or controlled to maintain PC 1 within its loaded position following step 801. As illustratively provided for according to FIG. 9B, the machinery used to hold mold base 100 may be the same machinery that controls the approach of mold cover 200 towards mold base 100 surface 100a. According to the illustrative embodiment of FIG. 9B, an exemplary mold cover 200 may also have a die pin 204 that may extend beyond mold cover surface 200a, while die pin 104 remains slightly below mold base surface 100a. Alternatively, and additionally, a clamping-type channel 207 may be provided in the mold cover 200 so as to force PC 1 into friction fit within the combination of clamping-type channel 207 and corresponding channel 107. An exemplary approach step 802 may be timed according to when PC 1 is secured within mold base 100 and/or channels 107 and/or cavities 102/103. Alternatively, an exemplary approach step 802 may take place once the means for loading PC 1 (manual or automated, i.e., by robotic armature with vacuum end effector) are no longer within the working zone 110a and/or disposed in front of mold base 100. Any of the illustrated features of FIGS. 9A-B or others that are described with respect to the same may be modified as needed to ensure proper holding of PC 1 within the volumes formed by the closed mold cavities formed by an exemplary mold base 100 and mold cover 200.
With reference to FIG. 9C, an exemplary closing step 803 may be illustrated showing the PC 1 held between one or more features (magnet source M, vacuum source VAC, clamping-type channel 207) of mold base 100 and/or mold cover 200 when surfaces 100a and 200a are in contact with one another. As shown in FIG. 9C, the closing step 803 may result in the formation of volumes partially occupied by either the terminus z and terminal regions of PC 1. Alternatively, any portions of a closed cavity that may not be filled with PC 1 may be substantially free of any injection molded material delivered during the process. Further alternatively, for any injected material that may find its way into the channel 107/207, it may be removed relatively readily easily through use and/or flexing of the resulting bendable PBB 10.
As shown in FIG. 9C, the closing step 803 may result in the formation of one or more types of PC 1 formations 1b/c/d/o/p/r/s/t/u/x by virtue of the difference in space between manipulating dies 104 and 204 and/or the action performed by dies 104/204 with respect to one another. For example, manipulating die 104 may maintain a support for PC 1 while manipulating die 204 performs one or more of the following operations either at separate parts of PC 1 or to the same part of PC 1 sequentially and/or simultaneously: (i) deflects PC 1 into a bend (formation 1b) or twist (formation 1t); (ii) deforms PC 1 into a different shape (formation 1c, formation 1d, formation 1p, formation 1r, formation 1x, formation 1u); (iii) removes a part of PC 1 to enable injected material to flow there through (formation 1o); and (iv) combinations of (i)-(iii).
With reference to FIG. 9D, an exemplary molding step 804 may be illustrated showing the injection of molten plastic (shown in hashed lines) into each cavity volume about the portions of PC 1 found therein to form BC 2 and EC 3 of PBB 10. The injection molding feeding system, while not illustrated, would be understood by those skilled in the art that injected material may flow into the mold cavities that will form BC 2 and EC 3 of PBB 10 either from a position that faces FIG. 9D (i.e., a position that is located out of the page and flowing into the page) or from a position that originates behind FIG. 9D (i.e., a position that is located behind the figure and flowing out of the page toward the viewer). As may be appreciated from FIG. 9D, the deformations 1x in the terminal regions of PC 1 and/or the crushed portion 1c formed via an exemplary closing step 803 may prevent the material making up EC 3 from dislodging from PC 1 when used. That is, the molding step 804 may enable injected material to intimately embed itself around and/or into the spaces formed by each deformation 1x, extension surface 1w, bend 1b, crushed section 1*, orifice 1o, pit 1p, and/or twist It in PC 1, and in particular, in the terminal region of the PC 1. According to an exemplary embodiment, an exemplary molding step 804 may involve injection of one or more of the following materials: PMMA, ABS, PA, PETG, PS, PC, PP, PE, PEEK, PET, PLA, cyanate esters, epoxies, polyesters, polyurethanes, silicones, rubbers, vulcanized rubbers, and combinations of the same. Alternatively, certain volumes formed by the closed mold halves may be filled with one type of material while other volumes may be filled with a different type of material during molding step 804.
With continued reference to FIG. 9D, it may also be appreciated that PC 1 may remain held by a clamping-type channel 207 and/or magnetic source M, which may be a specifically designed magnetic source that can resist repeated high temperatures (e.g., a high temperature neodymium permanent magnet or a steel core electromagnet with windings located on another side of the mold 100/200 in which it is found). In one aspect, the vacuum source VAC previously used to stabilize PC 1 as per FIGS. 9A-C, may be turned off during an exemplary molding step 804 to avoid injected material from being drawn into the passages 122. However, those skilled in the art may “close” the vacuum passage 122 using an ejector pin in the passage 122 in much the same way that any ejector pin passage 121 may similarly be closed during an exemplary molding step 804.
With reference to FIG. 9E, an exemplary release step 805 and ejecting step 806 may be illustrated showing the removal of mold cover 200 from contact with mold base 100 and the use of ejector pins 124 to eject the finished posable PBB 10 from the molds 100/200. As may be illustrated in FIG. 9E, the PBB 10 may be ejected in the configuration in which PC 1 was inserted. In other words, if PC 1 was inserted into mold base 100 as a substantially straightened PC 1, then PBB 10 may be ejected in a substantially straightened conformation.
While cavities 102/202 and/or 103/203 may have been illustratively shown as cylindrical elements, the methodologies and teachings may be used to anchor an exemplary PC 1 within any type of building block known to those skilled in the art for which injection molding or other forms of molding are appropriate. For example, cavity 102/202 may each be one half of the negative of a Lego® block while cavity 103/203 may each be one half of the negative of a K'nex® building piece. Any building block or building toy component known to those skilled in the art may have a cavity 102/202/103/203 made of it in an exemplary mold 100 and mold half 200. If a three-piece mold or a greater number of mold parts are necessary to form a particular cavity 102/202/103/203, those skilled in the art would be capable of implementing the inventive embodiments herein as long as at least two of any plurality of mold parts can serve as a mold 100 and/or 200.
Alternatively, the cavities 102/202/103/203 may be formed into various different types of shapes beside those of building blocks or toys. In other words, the inventive methodologies disclosed herein may allow for insertion-molded figurines with bendable PC 1 interconnecting their parts between gaps. Provided there are cavity partitions 108/208 between the various components 102/202/103/203 in the final structure, any part capable of being formed by injection molding may be made bendable by the processes, mold designs, and molding methods disclosed. In an exemplary embodiment, a single mold 100/200 may be prepared with a plurality of PC 1 resting in channels 107/207 and/or being disposed in cavities 103/203/102/202 shaped in parts of the body of an action figure or other play item (e.g., a skeleton of a stuffed animal or other mode). The aforementioned example may be achieved so long as the end parts or pieces of any particular figure, model, or construction follow the designs and teachings disclosed related to EC 3, BC 2, mold 100, and mold cover 200. As previously disclosed, other parts of the particular figure, model, or construction that would be analogous to BC 2 may be configured to receive and hold PC 1 therein for the molding process. With appropriate sizing and shaping of cavities 102/202/103/203, placement of channels 107/207, and dimensioning of cavity partitions 108/208, any bendable structure 30 comprised of a plurality of PC 1 may be fabricated using molds of the kind illustrated in FIGS. 10A-B to form objects of the kind illustrated in FIGS. 10C-D.
In an exemplary construct 30, there may be a shared body (“SB”) 2S or a body ender (“BE”) 32. An SB 2S may comprise two separate portions of different PC 1 embodied within the same material making up the SB 2S. Either one of the PC 1 embodied in an exemplary SB 2S may be fixed within it by virtue of a deflection or deformation (1b/c/d/o/p/r/s/t/u/x), although it may be the case that no PC 1 embodied within an exemplary SB 2S is anchored to the product. In contrast, a BE 32 comprises the terminal region of at least one exemplary PC 1 to allow anchoring of the same therein but will also contain other PC 1 types, including those without any means for anchoring in the BE 32 material. An exemplary construct may be illustratively shown via FIGS. 10C-D having a plurality of PC 1 (e.g., PC 1A, 1B, and 1c) that may be used to interconnect one or more of exemplary BC 2, SB 2S, BE 32, and EC 3. Alternative construct 30 may be illustrated and described with respect to FIGS. 9C-D of U.S. patent application Ser. No. 17/561,926, the disclosures of which are incorporated herein by reference in their entirety.
According to the exemplary embodiment illustrated by FIGS. 10C-D, an exemplary construct 30 may take the form of a figure or other toy having a plurality of appendages formed by a plurality of PC 1 made as either BC 2 and/or EC 3. For example, an exemplary construct 30 may have a first system of BC 2A and SB 2S and EC 3A1, 3A2 interconnected by PC 1A. In an exemplary embodiment, EC 3A1 and 3A2 may serve as the hands of construct 30 and may have one or more extensions 25 or 27. EC 3A1 and 3A2 may have the core features of an exemplary EC 3 in common, but may differ in terms of their shape, connection features, contours, material, and/or other surface characteristics. In other words, the EC 3A1, 3A2, 3B, 3C1, and 3C2 illustratively provided for in FIGS. 10C-D may be substantially the same as an exemplary EC 3 disclosed and illustrated elsewhere in this application, such as, (i) each may have at least one opening 4 and one or combinations of portion 1b/c/d/o/p/r/s/t/u/x along the PC 1 embedded therein; or (ii) each may have no opening 4 and one or combinations of portion 1b/c/d/o/p/r/s/t/u/x along the PC 1 embedded therein. The exemplary construct 30 of FIGS. 10C-D may also have a second system comprising an SB 2S, EC 3B, and BE 32 interconnected by PC 1B. An exemplary SB 2S may comprise a volume in which the PC 1A of the first system and the PC 1B of the second system co-exist in any like manner so as not to inhibit the posing and flexing properties of either of the PC 1A and/or 1B. In other words, an exemplary shared SB 2S may house within itself a plurality of embedded portions 1e (as shown in FIG. 10D by example as portions 1eA, 1eB, and 1eC, which are embedded portions of PC 1A, 1B, and 1D, respectively, made visible through transparent shared SB 2S) such that a plurality of flexible and posable connections and intersections may exist via the shared BC 2S. Further, an exemplary construct 30 of FIGS. 10C-D may have a third system comprising EC 3C1 and 3C2, which may be similarly configured and capable of making use of the optional designs and arrangements discussed with respect to EC 3A1 and 3A2. An exemplary PC 1D may couple the exemplary third system of construct 30 to the remainder of the construct 30 systems. Alternatively, an exemplary PC 1B and/or 1D may extend from end component to end component through SB 2S in much the same way as PC 1A.
In an exemplary embodiment, as shown in FIGS. 10A-B, an exemplary mold 100 may be illustrated for an exemplary construct 30. End cavities 103A1 and 103A2, and shared body cavity 102S may correspond to components 3A1, 3A2, and 2S of the exemplary first system of FIGS. 10C-D, respectively. End cavity 103B, shared body cavity 102S, and body-end cavity 132 may correspond to EC 3B, SB 2S, and BE 32 of the exemplary second system of FIGS. 10C-D, respectively. End cavities 103C1 and 103C2, body end cavity 132, and body cavities 1021 and 1022 may correspond to components EC 3C, BC 21, BE 32, BC 22, and EC 3C1 of the exemplary third system of FIGS. 10C-D, respectively. As may be further illustrated, an exemplary mold 100 may possess channels 107A, 107B, and 107C into which PC 1A, 1B, and 1C of the first, second, and third systems may be reposed before their cavity-traversing portions are over-molded with plastic to become embedded therein as previously described and also described with respect to FIGS. 9A-H of U.S. patent application Ser. No. 17/561,926, the disclosures of which are incorporated herein by reference in their entirety. An exemplary manipulating die 104 may be shown in EC 103A1, although such a die 104 may appear in any of the cavities of the exemplary mold 100 to allow for multi-PC 1 retention and deformation processes. It should be understood that a construct 30 may be of an infinite number of different forms and structures, which necessarily will require channels 107 to sometimes be unique and non-uniform in length or other dimension. Furthermore, any features previously disclosed with respect to mold 100 and/or 200 of FIGS. 8A-B and FIGS. 9A-E may also be included in the mold 100 and/or corresponding mold 200 (not shown) related to FIGS. 10A-B in like or similar kind, functionality, and placement.
An exemplary PBB 10, combination 20, and construct 30 may be used with numerous add-ons and connections to increase use and enjoyment of systems made thereby. For example, any part or component of any known toy or figure, sculpture, or three-dimensional work known to those skilled in the art may be divided into a plurality of pieces and, with the disclosures herein, be configured to adhere to an exemplary PBB 10, combination 20, and/or construct 30. For example, as illustrated in FIGS. 11A-B, two sculpture halves 40A and 40B may be halves of a shell 45 belonging to a single toy or figure, sculpture, or three-dimensional work or a portion of the same. In an exemplary embodiment, each half 40A/B may each have a sculpted surface 42 and a mounting surface face 41 separated by a material thickness 43. Exemplary halves 40A/B may be configured to use connectors 44 extending from the mounting surface 41 to attach onto one or more surface(s) of an exemplary PC 1, BC 2, and/or EC 3. In an exemplary embodiment, each connector 44 of the respective halves 40A and 40B may be positioned to cither clip, slip, attach, or otherwise mold around the same or an adjacent cross-section of an exemplary BC 2 and/or EC 3 such that the two halves 40A and 40B may be brought together to form a friction-coupled shell 45 about a portion of PBB 10. As illustrated in FIG. 11B, an exemplary shell 45 may resemble what would have otherwise been formed as an integral whole or part of a toy or other three-dimensional work. Accordingly, the shell 45 results in an increased variety of toy and three-dimensional work fabrications (e.g., mixing and matching shells) with a decreased cost in manufacturing such toys and/or three-dimensional works using typical screws, bolts, and hinges. An exemplary PBB 10, whether as part of a combination 20 or a construct 30, may therefore allow for users to build their own figurines from halves 40A/B that when connected to one another form one or more shells 45 of figurine parts and, in sufficient size and quantity of shells 45, forming whole toys, figurines, or other three-dimensional structures. While connectors 44 may be illustrated as clips, they may take the form of other friction-based couplings as well as threaded features, grooves, hooks, Lego-type interconnections, magnets, Velcro®, and/or snap-fit. For example, one half 40A may be the front-facing chest portion of an action figure, half 40B is the rear facing chest portion of that action figure, and when halves 40A and 40B are coupled by clipping or passing PBB 10 through an opening, the complete chest of the action figure, which is a shell 45, would result.
Referring to the illustrative embodiment provided for by FIG. 11C, an exemplary PBB 10 may be dimensioned and sized to hold a fabric body 50 via through-holes 52 formed by pieces of fabric in the body. An exemplary fabric body 50 may be a cloth piece Lego Part Number 86297. An exemplary PBB 10 may use the portions of PC 1 found in the gaps 8 between each of the internal faces 5 of BC 2 to retain the fabric holes 52 of an exemplary cloth part or fabric accessory 50 and provide structure to the fabric's otherwise flimsy and flowing texture. As such, the exemplary PBB 10 described may be used to form wings, tails, webs, and other intricate patterns using the fabric 50 via the interconnections between exposed wire portions 1 and openings 52 in the fabric 50.
Additionally, the PC 1 may be electrically conductive to transmit low voltages to illuminate one or more translucent BC 2/EC 3 or other conductive parts in contact therewith. Further, any exposed PC 1 portions of any PBB 10, combination 20, and/or structure 30 may be subsequently coated via post-processing (e.g., elastomer dips, paints, fabric coverings) or otherwise covered (as per the rubber cover discussed with respect to FIGS. 6G-I). In an exemplary embodiment, PC 1 may be an insulated LED wire string (e.g., have a coating thereon), such as the kind made and sold by Twinkle Star. As such, the PC 1 may be pinched, constrained, and insertion molded in the same or similar molds and methods ways as previously described for PC 1 in FIGS. 8A-B, 9A-E, and 10A-B, and all manufacturing methods disclosed and illustrated in U.S. patent application Ser. No. 17/561,926, the disclosures of which are incorporated herein by reference in their entirety. Alternatively, an insulated PC 1 may be stripped at its ends, which may be the locations of deformed portion 1d or the situs of a crushed section 1c. In an aspect of this exemplary embodiment, opening 4 may provide electrical contact between the exposed wire portions of insulated PC 1 so as to use an exemplary PBB 10 as circuit wire. As such, an exemplary PBB 10 may have additional benefits in terms of being able to allow a part to be inserted through opening 4 of EC 3 (e.g., via a connection to a current-carrying building block or other component with electrical contacts) to pass current through the formation in PC 1 located through opening 4, while the remainder of PC 1 passing through each BC 2 until the next EC 3 may be insulated to allow current to pass there through without incident.
According to the illustrative embodiments of FIGS. 12A-C, an exemplary PBB 10 may be fabricated using additive manufacturing processes, such as, for example, 3D printing (which terms may be used interchangeably to refer to the same processes). In a first step illustrated by FIG. 12A, an exemplary additive manufacturing process may form base layers 2q and 3q having receiving layers 2r and 3r, respectively, atop a work surface 1000. Unlike base layer 2q, a base layer 3q may have a barrier end 6q and a terminal receiving layer 6r. Exemplary base layers 2q and/or 3q may be manufactured using any additive manufacturing devices or methods known to those skilled in the art. Exemplary base layers 2q and/or 3q may also be made out of any material useable with such additive manufacturing devices. According to an exemplary embodiment, each of the base layers 2q and 3q of FIG. 12A may be still molten and/or not fully cured so that additional material may continuously be added to the cupped features throughout the process until completed.
In a second step illustrated by FIG. 12B, an exemplary PC 1 may be placed into the receiving layers 2r of each base layer 2q while its terminal region is placed into the base layer 3q within receiving layer 3r. Such placement is contemplated while each feature of the base layers 2q/3q is still substantially able to be built upon through additive manufacturing. An exemplary posable component 1 may be pre-deformed to have a deformed portion 1d adjacent the terminus 1z. In an exemplary embodiment, the terminus 1z may be substantially flush or at a minimum will not exceed the boundary 6q and terminal receiving layer 6r.
In a third step illustrated by FIG. 12C, an exemplary PC 1 resting within the receiving layers 2r and 3r atop base layers 2q and 3q, respectively, may be enclosed within the base layers by corresponding completion layers 2p and/or 3p using the same or different 3D printed material. According to this exemplary embodiment, molten material will be layered on top of posable component 1 so that it may fill whatever surfaces that may exist on posable component 1 as a result of deformed portion 1d, bend 1b, twist 1t, pit 1p, and/or orifice 1o.
According to the illustrative embodiments and steps of FIGS. 12A-C, an exemplary PC 1 may be placed in the base layers 2q/3q and between the receiving layers 2r, 3r, and 6r in a sufficient amount of time to achieve a completion layer 2p/3p that will be integral with the receiving layers and the base layers. In a preferred embodiment, the PC 1 may be placed in the base layers 2q/3q and within receiving layers 2r/3r, respectively, in approximately 1-2 minutes leaving only one minute for the additive manufacturing of the completion layers 2p/3p to begin. Depending on the curing times of the filament used to create base layers 2q and 3q, those skilled in the art would understand to time the supply of PC 1 to the 3D printing process so that it reduces the chance of full curing of the base layers 2q/3q and/or receiving layers 2r/3r. While the process illustrated by FIGS. 12A-C may be shown as involving only one PC 1, those skilled in the art would be able to follow the prior mass manufacturing disclosures to enable large-scale additive manufacturing of an exemplary PBB 10, e.g., by using vacuum-based pick-and-place robotics and a PC 1 straightening and cutting system.
It should be understood that the embodiments using the enumerated structures, features, and methods described are not limited to those expressly disclosed and/or illustrated, but encompass all varieties and variations. First, every feature in any figure may be used in place of the same or a similar feature in another figure or embodiment, unless otherwise expressly limited by function. Second, every physical feature in any figure may be used in conjunction with any other feature in any other figure such that all permutations achievable by such conjunctive use are hereby disclosed and contemplated. Third, to the extent reference is made to a particular building block, figurine, toy, or other similar structure, it should be understood that all known building blocks, figurines, toys, and any other similar structures are equally applicable and may be substituted in place of any expressly disclosed building block, figurine, toy, or other similar structure used by or formed by the disclosed features herein, e.g., any halves 40 and/or shells 45 of any three-dimensional structure or work. Fourth, all sizes and dimensions of any embodiment are contemplated without restriction unless otherwise stated. Fifth, all embodiments may be used to modify any other embodiment to achieve a desired purpose, whether or not the desired purpose is expressly stated.
Many further variations and modifications may suggest themselves to those skilled in art upon making reference to above disclosure and foregoing interrelated and interchangeable illustrative embodiments, which are given by way of example only, and are not intended to limit the scope and spirit of the interrelated embodiments of the invention described herein.
Patent Application
20250058242
