Patent Application
20250065243
The present disclosure relates to toy elements which can provide for a range of play and learning experiences.
Toys, in all shapes and sizes, are enjoyed by many children (and adults) around the world. Playing with toys entertains children and can also positively contribute to their physical and mental development. Providing novel toys for children, particularly those that have potential to increase the variety of play possibilities and/or improve the child's tactile engagement and learning, can be a beneficial contribution to the art.
Embodiments of the building unit of a toy building set are described in further detail below with reference to the following drawings, in which:
This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the disclosure.
The following terms shall have, for the purposes of this application, the respective meanings set forth below. Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.
As used herein, the singular forms “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise. Thus, for example, reference to a “cell” is a reference to one or more cells and equivalents thereof known to those skilled in the art, and so forth.
As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50 mm means in the range of 45 mm to 55 mm.
As used herein, the term “consists of” or “consisting of” means that the device or method includes only the elements, steps, or ingredients specifically recited in the particular claimed embodiment or claim.
In embodiments or claims where the term “comprising” is used as the transition phrase, such embodiments can also be envisioned with replacement of the term “comprising” with the terms “consisting of” or “consisting essentially of.”
As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein are intended as encompassing each intervening value between the upper and lower limit of that range and any other stated or intervening value in that stated range. All ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, et cetera. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, et cetera. As will also be understood by one skilled in the art, all language such as “up to,” “at least,” and the like include the number recited and refer to ranges that can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 components refers to groups having 1, 2, or 3 components as well as the range of values greater than or equal to 1 component and less than or equal to 3 components. Similarly, a group having 1-5 components refers to groups having 1, 2, 3, 4, or 5 components, as well as the range of values greater than or equal to 1 component and less than or equal to 5 components, and so forth.
In addition, even if a specific number is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, et cetera). In those instances where a convention analogous to “at least one of A, B, or C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, et cetera). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, sample embodiments, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
While the present disclosure has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, the Applicant does not intend to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the disclosure in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the Applicant's general inventive concept.
In some embodiments, an aim of the building units can be to provide users such as children with new toys and play opportunities, such as, but not limited to, ones that contribute to the children's tactile engagement and learning. In this regard, disclosed herein are building units of a toy building set. Each building unit can comprise a sheet of a material that can define a net of a polyhedron, the sheet having a plurality of sections, each section being connected to another section with a hinge. The building unit can be configured to fold at the hinges from a flat configuration into a polyhedron with a hollow interior. The building unit can also comprise a plurality of joins on outer edges of the building unit, each join can comprise one or more teeth configured to interleave with teeth of another join and releasably connect the sections of the building unit to form edges of the polyhedron. The sections, hinges and joins can all be provided on one piece of the same material.
The building unit can be initially provided in the form of flat sheet of material, which can be folded into a three-dimensional shape for subsequent use. Such toys may provide a user with a tactile learning experience gained during the formation of a polyhedron from its planar net shape. The product may subsequently be used in further play, both on its own and in combination with other toy elements disclosed herein.
As will be described in further detail below, these toy building units can also contain a number of surfaces on which a user can draw or personalise in the manner described in further detail below. Furthermore, by having a hollow interior in the closed position, these toy building units may be used to contain other toys.
The building unit may be manufactured using a cutting process, a molded process, or combinations thereof. The building unit may comprise or be formed from cardstock, cardboard, bagasse, wood, laminate, plastic, extruded foam sheet, vellum, rubber, plasticized pulp, moulded pulp, pulp, or any combination thereof.
Any suitable material may be used for producing cut building units with cut and/or crimped hinges. For example, pulp (such as bagasse) may be tray molded (not injection molded) and may be molded or pressed into sheets and cut, or may be molded into building units with integral hinges. White boxboard sheet and thermally pressed, tray molded pulp may offer the highest quality/price combination. Other suitable example sheet materials include styrene sheets, polylactic acid (PLA) sheets or PLA foam which may be extruded into sheets.
Examples of plastic materials which may be used include poly(methyl methacrylate) (PMMA), nylons (e.g. polyamide), polycarbonate (PC), polyethylenes (e.g. PE, HDPE), polyoxymethylene (POM), polystyrene (PS), polybutylene adipate terephthalate (PBAT), polycaprolactone (PCL), polyhydroxyalkanoates (PHAs), polypropylene (PP), thermoplastic elastomers (e.g. TPS) and polylactic acid (PLA). Such plastics may be suitable for producing building units via injection moulding. Acrylonitrile butadiene styrene (ABS) may also be used.
Bio-plastics, which are designed to substitute plant-based inputs for the petroleum inputs in polyethylene, polypropylene, polylactic acid and other plastics, may be a suitable long term sustainable alternative for building units which are injection molded or cut from sheeting. Composites of starch and bioplastic, wood and bioplastic, and other biomass and plastic composites are emerging materials that may also be suitable for building units.
As described above, the building unit includes a plurality of sections, each of which is connected to another section via a hinge. The hinges can be foldable, thereby enabling the building unit to be folded by a user from its flat configuration into its three-dimensional polyhedron configuration.
The hinges may, for example, include a groove on one surface of the building unit in the flat position and a ridge on an opposite surface of the building unit in the flat position. Such a hinge structure may enable users (e.g., children) to perform the necessary folding actions more easily. Alternatively, the hinges may include a first groove on one surface of the building unit in the flat position and a second groove on an opposite surface of the building unit in the flat position. Alternatively, the hinges may include a partial cut through the sheet of material. Such a hinge structure is simpler and hence easier to form than more complicated hinges.
A groove which comprises a hinge structure may be formed by molding, cutting or applying pressure to the material.
The building unit can also comprise a plurality of joins on outer edges of the building unit. Each join can comprise one or more teeth configured to interleave with teeth of another join and thus releasably connect the sections of the building unit to form edges of the polyhedron.
The joins of the building unit may comprise curved or straight teeth. The joins may be configured to interlock with or without a design overlap, which may require teeth sides to compress to interleave and which may increase static friction to help retain the building unit in a closed position during play.
The teeth may be an integral extension of a same material as the sections; wherein the one or more integral teeth, joins, and sections may have a same thickness and may be configured so that the building unit in the flat position may be formed by a die cutting through a sheet of material. A building unit may be cut from a sheet of material by a laser cutter or a digital blade cutter.
The building unit may be held in the closed position (i.e., in its polyhedron shape) by paired joins. The joins may connect the sections of the building unit forming edge connections without adhesive to create the three-dimensional hollow building unit. The one or more interleaved teeth in a paired join may be configured to be visible on an exterior of the building unit in the closed position. In some embodiments, the joins can readily be opened by a user wanting to access an interior of the unit.
The closed position of the building unit can be a predetermined polyhedron. In the building unit, the one or more interleaved teeth of the paired joins may be configured to engage with each other to form the predetermined polyhedron in response to a fold at the at least one hinge from the flat position into the closed position.
The building unit may for example comprise or be a cuboid unit. A cuboid unit can comprise five hinges and fourteen joins. The fourteen joins, when closed, may form seven edges of the cuboid; and the five hinges can form five edges of the cuboid
The building unit may for example comprise or be a square based pyramid. The square based pyramid may comprise four hinges and eight joins. The eight joins, when closed, may form four edges of the square based pyramid; and the four hinges may form four edges of the square based pyramid.
The building unit may for example comprise a triangular prism. The triangular prism may comprise four hinges and ten joins, wherein the ten joins, when closed, form five edges of the triangular prism; and the four hinges may form four edges of the triangular prism. Other polyhedrons may be formed from the building units of the present invention, examples of which will be described below.
The building unit may for example be a three-dimensional hollow building unit which may comprise a curved surface, for example, one created by a series of hinges in close proximity, or by a flexible sheet of material being constrained in a curved configuration.
In some embodiments, one or more of the sections of the building unit may have a dimension that is N×about 8 mm, where N is a whole number. As used herein, the term “about” is to be understood as meaning ±10% of the recited value. Building units having such a size are compatible with other toy systems, such as those described below, thereby enabling additional play opportunities as the building units can be co-mingled with parts of other toy systems.
Disclosed herein is a building unit of a toy building set, where the building unit may comprise: at least two sections, wherein each section may be connected to another section with at least one hinge, wherein a number of sections may be equal to one plus a number of hinges, wherein the building unit may be configured to fold over multiple cycles at the at least one hinge from a flat position into a at least one open position or a closed position, wherein the closed position may be a three-dimensional position with a hollow interior.
The hinges may be configured as a groove on one surface of the building unit in the flat position and as ridges on an opposite surface of the building unit in the flat position. Alternatively, the hinges may be provided as partial cuts through a sheet of material configured to be visible on an exterior of the building unit in the closed position. Alternatively, the hinges may be configured as a first groove on one surface of the building unit in the flat position and as a second groove on an opposite surface of the building unit in the flat position. The at least two joins integral to outer edges of the building unit in the flat position may be configured to be brought together in pairs to form edges of the building unit in the closed position. The at least two joins may have one or more integral teeth. The at least two sections, the at least one hinge, the at least two joins, and the one or more integral teeth may be one piece. The one or more integral teeth of paired joins may be configured to interleave to form a closed edge of the building unit in the closed position such that friction between surfaces of one or more interleaved teeth may hold the building unit together in the closed position. A friction fit edge may be configured to unpair by a pulling apart one or more interleaved teeth. In some embodiments, in all positions of the building unit, the one or more integral teeth may be configured to retain a fixed orientation relative to their integral join and their integral section.
The building unit in the flat position may have at least one point where two hinges meet two joins of a join pair; and wherein the one or more integral teeth of each join of the join pair may be configured to interleave in a predetermined position. For example, the predetermined position may be a cuboid and a perimeter of the building unit in the flat position has at least one point where two hinges may meet two joins at four right angles.
Also disclosed herein is a building unit of a toy building set, wherein the building unit may comprise: at least two sections, wherein each section may be connected to another section with at least one hinge, wherein a number of sections may be equal to one plus a number of hinges, wherein the building unit may be configured to fold over multiple cycles at the at least one hinge from a flat position into a at least one open position or a closed position, wherein the closed position may be a three-dimensional position with a hollow interior.
Each of the at least one hinge may include partial cuts through a sheet of material configured to be visible on an exterior of the building unit in the closed position. At least two joins integral to outer edges of the building unit in the flat position may be configured to be brought together in pairs to form edges of the building unit in the closed position. The at least two joins have one or more integral teeth. The at least two sections, the at least one hinge, the at least two joins, and the one or more integral teeth may be one piece. The one or more integral teeth of paired joins may be configured to interleave to form a closed edge of the building unit in the closed position such that friction between surfaces of one or more interleaved teeth may hold the building unit together in the closed position. A friction fit edge may be configured to unpair by a pulling apart one or more interleaved teeth. In some embodiments, in all positions of the building unit, the one or more integral teeth may be configured to retain a fixed orientation relative to their integral join and their integral section.
Also disclosed herein is a building unit of a toy building set, wherein the building unit may comprise: at least two sections, wherein each section may be connected to another section with at least one hinge, wherein a number of a section may be equal to one plus a number of hinges, wherein the building unit may be configured to fold over multiple cycles at the at least one hinge from a flat position into a at least one open position or a closed position, wherein the closed position may be a three-dimensional position with a hollow interior.
The hinges may be configured as a groove on one surface of the building unit in the flat position. At least two of joins integral to outer edges of the building unit in the flat position may be configured to be brought together in pairs to form edges of the building unit in the closed position. The at least two joins may have one or more integral teeth. The at least two sections, the at least one hinge, the at least two joins, and the one or more integral teeth may be one piece. The one or more integral teeth of paired joins may be configured to interleave to form a closed edge of the building unit in the closed position such that friction between surfaces of one or more interleaved teeth may hold the building unit together in the closed position. A friction fit edge may be configured to unpair by a pulling apart one or more interleaved teeth. In some embodiments, in all positions of the building unit, the one or more integral teeth may be configured to retain a fixed orientation relative to their integral join and their integral section. The one or more interleaved teeth in a paired join may be configured to be visible on an exterior of the building unit in the closed position.
Also disclosed herein is a building unit of a toy building set, wherein the building unit may comprise: at least two sections, wherein each section may be connected to another section with at least one hinge, wherein a number of sections may be equal to one plus a number of hinges, wherein the building unit may be configured to fold over multiple cycles at the at least one hinge from a flat position into a at least one open position or a closed position, wherein the closed position may be a three-dimensional position with a hollow interior.
At least two of joins integral to outer edges of the building unit in the flat position may be configured to be brought together in pairs to form edges of the building unit in the closed position. The at least two joins may have one or more integral teeth. The at least two sections, the at least one hinge, the at least two joins, and the one or more integral teeth may be one piece. The one or more integral teeth of paired joins may be configured to interleave to form a closed edge of the building unit in the closed position such that friction between surfaces of one or more interleaved teeth may hold the building unit together in the closed position. A friction fit edge may be configured to unpair by a pulling apart one or more interleaved teeth. In some embodiments, in all positions of the building unit, the one or more integral teeth may be configured to retain a fixed orientation relative to their integral join and their integral section. The one or more interleaved teeth in a paired join may be configured to be visible on an exterior of the building unit in the closed position. The outer edges of the building unit in the flat position may be surfaces perpendicular to a top surface of the building unit in the flat position and perpendicular to a bottom surface of the building unit in the flat position.
Also disclosed herein is a building unit of a toy building set, wherein the building unit may comprise at least four polygonal sections, wherein each section may be connected to another section with at least one integral hinge.
The building unit may be configured to fold and unfold over multiple cycles at the hinges from a flat position into a closed position which may be a polyhedron with a hollow interior. The tips and sides of at least two integral teeth may comprise outer edges of the building unit in the flat position. Friction between the sides of the integral teeth may hold the building unit in the closed position. The tips of the one or more integral teeth may be visible on the exterior of the building unit in a closed position. In some embodiments, in all positions of the building unit, the tips of the one or more integral teeth may be configured to retain a fixed orientation relative to their integral section.
In the closed position, sides of teeth engaged in friction fit may be configured with design overlap which causes the sides to compress or deform.
The building unit in the flat position may have an exterior surface, an interior surface, and an outer edge; wherein the exterior surface may be visible on the exterior of the building unit in the closed position; wherein the exterior surface may be a material receptive to pencil, crayon or ink drawing.
Also disclosed herein is a building unit of a toy building set, wherein the building unit may comprise at least four polygonal sections, wherein each section may be connected to another section with at least one integral hinge.
The building unit may be configured to fold and unfold over multiple cycles at the hinges from a flat position into a closed position which may be a polyhedron with a hollow interior; wherein the tips and sides of at least two integral teeth may comprise outer edges of the building unit in the flat position. Friction between the sides of the integral teeth may hold the building unit in the closed position. The tips of the one or more integral teeth may be visible on the exterior of the building unit in a closed position. In the closed position sides of teeth engaged in friction fit may be configured with design overlap which causes the sides to compress or deform.
Specific forms of the building unit will be described below with reference to
Provided herein is a toy building unit for playing capable of folding from a flat configuration or position into a three-dimensional hollow configuration or position held together only by friction. Methods of manufacturing the same are also described.
In some embodiments, the building unit 100 can be in a flat position 102, a partially constructed position, a three-dimensional hollow position 108, a closed position, or an open position. In some embodiments, the building unit 100 in a closed position can be the building unit in a three-dimensional hollow position 108. In some embodiments, the building unit 100 in an open position can be the building unit 100 in a partially constructed position such that at least one section 104 has an edge which is a join 110 that is not paired with (e.g., not connected with) another join 110. In some embodiments, closure of the building unit 100 (e.g., the building unit in a partially constructed position or a three-dimensional hollow position 108), can provide structural rigidity.
In some embodiments, the building unit 100 can include a plurality of sections 104. In some embodiments, the building unit 100 can include 3 to tens, or any value or range between, or more sections 104. In some embodiments, the sections 104 can be, but are not limited to, square, rectangular, semicircular, triangular, oblong, pentagonal, hexagonal, diamond, trapezoidal, octagonal, or any other suitable shape. In some embodiments, the sections 104 can be rigid, flexible, or pliable, or capable of forming an arc. In some embodiments, the plurality of sections 104 can be delineated from and connected to at least one other section 104. In some embodiments, a section 104 can be connected to another section 104 by at least one hinge 106. In some embodiments the at least one hinge 106 can be integral to the building unit 100. In some embodiments, integral can mean that the sections and the hinges are one piece of a same material. In some embodiments, integral can mean that the building unit 100 can be made such that all of the sections and all of the hinges are made of one material that can start in a flat or two-dimensional position and fold into a three-dimensional hollow position 108. In some embodiments, integral can mean that hinges 106 can be part of the building unit 100 and can be manufactured in one piece of a same material, as shown in
In some embodiments, the building unit 100 can include a plurality of hinges 106. In some embodiments, the hinge 106 can be integral to the building unit 100. In some embodiments, the hinge 110 can be a living hinge. In some embodiments, the hinge 110 can be a partial cut. In some embodiments, the hinge 110 can be a small indent at a stress point aligned collinearly on the building unit 100 rather than cutting the thickness of the building unit 100 entirely. In some embodiments, the hinge can appear as a groove viewing one surface of the building unit 100 and a ridge when viewing the opposite surface of the building unit 100. In some embodiments, a hinge 106 can connect two sections 104 of the building unit 100. In some embodiments, the hinge 106 can bend to an angle when the building unit is in a three-dimensional hollow position 108. In some embodiments, the angle of the hinge 106 when the building unit is in a closed position 108 can be about a 15° angle to about a 200° angle or any range or value between. In some embodiments, one or more hinge 106 can be removed. In some embodiments, one or more hinge 106 can be removably attached. In some embodiments, one or more hinge of the building unit 100 can be replaced by two joins 110.
In some embodiments, the building unit 100 can include a plurality of joins 110. In some embodiments, the join 110 can be a zip join, a finger join, or any other suitable join. In some embodiment, a join can include one or more teeth. In some embodiments, the joins 110 may be along the perimeter of the building unit 100. In some embodiments, the edges of a section 104 of a building unit 100 can include one or more joins 110 corresponding to one or more edges of the section. In some embodiments two joins 110 may be interleaved. In some embodiments, two joins 110 interleaved can hold together two or more sections 104 of the building unit 100. In some embodiments, two or more joins 110 can be reversibly opened and closed. In some embodiments, joins 110 can enable closure of building unit in a three-dimensional hollow position 108. In some embodiments, joins 110 can enable partial closure of building unit 100. In some embodiments, two or more joins 110 can be held together by friction. In some embodiments, closure of building unit 100 can be enabled by friction among joins 110. In some embodiments, closure of building unit 100 can be reversable and repeatable. In some embodiments, joins 110 can have no teeth 112, but latching ridge or similar mechanism among joins 110 can connect two or more sections 104 of the building unit 100 into a closed position. In some embodiments, joins can have one or more teeth 112.
In some embodiments, hinges 106 and joins 110 can be features of the building unit 100 in a flat position 102 and of the building unit in a three-dimensional hollow position 108.
In some embodiments, the building unit 100 can include one or more teeth 112. In some embodiments, the building unit 100 can include one or more teeth at each join 110 outlining the outer edges of sections 104 of the building unit. In some embodiments, join 110 can include the one or more teeth 112. In some embodiments, teeth 112 can be integral to joins 110 and grip one or more opposing teeth 112 (e.g., teeth integral to another join 110 on another different section 104 such that the two joins are paired to form an edge of the building unit in a three-dimensional hollow position 108). In some embodiments a join 110 can include about 0 teeth 112 to about 100 teeth 112 or any range or value between. In some embodiments the teeth 112 can be curved, angled, and/or straight. In some embodiments, teeth 112 can include ridges, grooves, spikes, protrusions, cavities, or other suitable shapes to enable paired joins to remain paired when the building unit is in a three-dimensional hollow position 108. In some embodiments, teeth 112 can have a thickness 113, a depth 114, and a width 115 as depicted in
In some embodiments, two teeth 112 can be about 15 mm wide, about 3 mm thickness, and about 3 mm depth. In some embodiments, three teeth can be about 5 mm wide, about 3 mm thick, and about 3 mm depth. In some embodiments, teeth have various widths and/or dimensions. In some embodiments, teeth 112 can be, for example, a quarter inch wide and a quarter inch tall/deep. In some embodiments, teeth 112 can be uniform or of different widths and depths. In some embodiments, teeth 112 can be rectangular. In some embodiments, teeth 112 can be rectangular rounded. In some embodiments, teeth 112 can be waves. In some embodiments, teeth 112 can be spikes. In some embodiments, teeth 112 can be protrusions. In some embodiments, teeth 112 can be latches. In some embodiments, joins 110 can comprise one or more angle-edge teeth 112, which function as a finger pull for ease of opening. In some embodiments the teeth 112 of the join 110 can be rounded on two axes for smooth interleaving and reduced friction. In some embodiments the teeth 112 of the join 110 can be rounded on one axis, which can create more friction than when teeth 112 are rounded on two axes. In some embodiments, there can be friction where the teeth 112 of two joins 110 come together, with the inner teeth 112 along the join edge providing more friction.
In some embodiments, the thickness of joins 110 and depth of the teeth 112 can vary for each material of the building unit 100. In some embodiments the joins 110 can be about 0.2 mm to tens mm thick, or any range or value between. In some embodiments, teeth 112 can be the same thickness as the joins 110. In some embodiments, the width 115 of teeth 112 can range from about 2 mm to tens mm wide, or any range or value between (e.g., between about 2-25 mm, such as about 5, 10, 15, 20 or 25 mm). In some embodiments, the depth 114 of the teeth 112 can be about 0.2 mm to tens mm deep, or any range or value between (e.g., about 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 mm). In some embodiments, the thickness 113 of the teeth 112 can be about 0.2 mm to about 10 mm, or any range or value between (e.g., about 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 mm).
In some embodiments, the thickness 113 of one or more of the teeth 112 of a join 110 on one section 104 can be about the same as the depth 114 of one or more of the teeth 112 of another join 110 on another section 104 which, in a right-angled join, presents a substantially continuous surface across the interleaved teeth for the entirety of the join. In some embodiments, the depth 114 and thickness 113 of the teeth can vary relative to the thickness of the material (e.g., sheeting or molded material) of the toy building unit 100, whereas the width 115 of the teeth 112 can be a fraction of the entire length of an edge of a section. In some embodiments, the minimum and/or maximum thickness of joins 110 and/or teeth 112, depth of teeth 112, and width of teeth 112 can vary for each material. In some embodiments, the minimum and/or maximum thickness of joins and depth of teeth can vary for each material of the building unit 100 such that the dimensions allow the building unit in a three-dimensional hollow position 108 to close properly and reversibly open.
In some embodiments, the building unit 100 can include one or more edges. In some embodiments, the edges can be the edges of the sections 104. In some embodiments, the edges of the sections 104 of the building unit 100 can be a join 110. In some embodiments, the edges of the section 104 can be un-joined joins 110. In some embodiments, the edges of the building unit 100 can be un-joined joins 110. In some embodiments, the edges can be the edges of the three-dimensional hollow building unit 114. In some embodiments, the edges of the three-dimensional hollow building unit 114 can be a hinge 106 that connects two sections 104 of the building unit. In some embodiments, the edges of the three-dimensional hollow building unit 114 can be two joins 110 that come together (e.g., interleaved, paired, clicked in place, removably attached, held together by friction, and the like) to form an edge of the three-dimensional hollow building unit 114.
In some embodiments, the closed joins 110 can create the building unit in a three-dimensional hollow position 108. In some embodiments, the closed joins 110 can connect the sections 104 of the building unit 100 to each other predominantly by static friction so that the resulting polyhedron remains closed during play. In other words, in some embodiments, the building unit in a three-dimensional hollow position 108 can remain closed by the static friction force in the closed joins 110 and thus there may be no need for glue, tucking, magnets, or any other means. In some embodiments, the closed joins 110 may be pulled open by an intentional manual force to return the building unit 100 unit to a flat position 102. In some embodiments, the transition between the building unit 100 in a flat position 102 with open joins to the building unit in a three-dimensional hollow position 108 with closed joins 110 may be reversible and repeatable. In some embodiments, the transition between the building unit 100 in a flat position 102 with open joins to the building unit in a three-dimensional hollow position 108 with closed joins may not be reversible and repeatable. In some embodiments, the transition between the building unit 100 in a flat position 102 with open joins to the building unit in a three-dimensional hollow position 108 with closed joins 110 may be partially reversible and repeatable such that some sections 104 feature joins 110 that can be opened and closed in a reversable and repeatable manner, while other sections 104 may feature joins 110 that cannot be opened and closed in a reversable and repeatable manner.
In some embodiments, the building unit 100 can fold from a flat position 102 into a three-dimensional hollow position 108. In some embodiments, the building unit in a flat position 102 can be described using the mathematical concept of a two-dimensional (2D) net. In some embodiments, the building unit in a flat position 102 can be described as a net, a 2D net, a net of a solid, a net of a polyhedron, a cut-out, a stencil, a paper sheet, or the like. A net is an arrangement of non-overlapping edge-joined polygons in the plane which can be folded (along edges) to become the faces of the polyhedron. Many different nets can exist for a given polyhedron, depending on the choices of which edges are joined and which are separated. Nets are known. For example, there are eleven nets of a cube, wherein each net is a unique arrangement of sections 104 of the net.
In some embodiments, the building unit 100 can be a cuboid, square based pyramid, triangular prism, domed cuboid, half cylinder, quarter cylinder, or any other three-dimensional shape (e.g., any polyhedron). In some embodiments, a three-dimensional hollow position 108 of the building unit 100 can be a cuboid, square based pyramid, triangular prism, domed cuboid, half cylinder, quarter cylinder, or any other three-dimensional shape (e.g., any polyhedron).
In some embodiments, the building unit 100 can be a cuboid. In some embodiments, the cuboid can be a cube where the ratio of width:length:height is equal. For example, in some embodiments that cuboid can be about 10 to about 1000 mm in width, length, and height. In some embodiments a cuboid can be an extended cube where one dimension of the width:length:height ratio is extended. In some embodiments, a cuboid can be a rectangular prism where one or more dimension of the width:length:height ratio is extended. In some embodiments, the cuboid unit can include five hinges 106 and fourteen joins 110. In some embodiments, the building unit 100 of the cuboid unit can include six sections 104. In some embodiments, the fourteen joins 110, when closed, form eight edges of the cuboid (e.g., edge of the three-dimensional hollow building unit 114) and the five hinges 106 form five edges of the cuboid (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the width of the cuboid can be about 10 mm to about 1000 mm. In some embodiments, the length of the cuboid can be about 10 mm to about 1000 mm. In some embodiments, the height of the cuboid can be about 10 mm to about 1000 mm.
In some embodiments, the building unit 100 can be a square based pyramid. In some embodiments, the square based pyramid can include four hinges 106 and eight joins 110. In some embodiments, the building unit 100 of the square based pyramid can include five sections 104. In some embodiments, the eight joins 110, when closed, form four edges of the square based pyramid (e.g., edge of the three-dimensional hollow building unit 114), and the four hinges 106 form four edges of the square based pyramid (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the base of the square based pyramid can be about 10 mm to about 1000 mm by about 10 to about 1000 mm. In some embodiments, the height of the square based pyramid can be about 10 mm to about 1000 mm at the tallest point.
In some embodiments, the building unit 100 can be a triangular prism. In some embodiments, the triangular prism can include four hinges 106 and ten joins 110. In some embodiments, the building unit 100 of the triangular prism can include five sections 104. In some embodiments, the ten joins 110, when closed, form five edges of the triangular prism (e.g., edge of the three-dimensional hollow building unit 114), and the four hinges 106 form four edges of the triangular prism (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the width of the triangular prism can be about 10 mm to about 1000 mm. In some embodiments, the length of the triangular prism can be about 10 mm to about 1000 mm. In some embodiments, the height of the triangular prism can be about 10 mm to about 1200 mm at the tallest point.
In some embodiments, the building unit in a three-dimensional hollow position 108 can include a volume with a cylindrically curved surface, with one section that curves into a three-dimensional position by flexing the material of the building unit 100 to connect to an adjoining section 104 on which the join 110 is curved. The flexibility of the curved section 104 can be enabled by the use of a flexible material to make the building unit 100, or by adding features such as ribbing or cuts into a rigid material.
In some embodiments, the building unit 100 can be a domed cuboid. In some embodiments, the domed cuboid can include five hinges 106 and fourteen joins 110. In some embodiments, the building unit 100 of the domed cuboid can include six sections 104. In some embodiments, the fourteen joins 110, when closed, can form seven edges of the domed cuboid (e.g., edge of the three-dimensional hollow building unit 114), and the five hinges 106 can form five edges of the domed cuboid (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the width of the domed cuboid can be about 10 mm to about 1000 mm. In some embodiments, the length of the domed cuboid can be about 10 mm to about 1000 mm. In some embodiments, the height of the domed cuboid can be about 10 mm to about 1200 mm at the tallest point.
In some embodiments, the building unit 100 can be a half cylinder. In some embodiments, the half cylinder can include three hinges 106 and six joins 110. In some embodiments, the building unit 100 of the half cylinder can include four sections 104. In some embodiments, the six joins 110, when closed, can form three edges of the half cylinder (e.g., edge of the three-dimensional hollow building unit 114), and the three hinges 106 can form three edges of the half cylinder (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the width of the half cylinder can be about 10 mm to about 1000 mm. In some embodiments, the length of the half cylinder can be about 10 mm to about 1000 mm. In some embodiments, the height of the half cylinder can be about 10 mm to about 1200 mm at the tallest point.
In some embodiments, the building unit 100 can be a quarter cylinder. In some embodiments, the quarter cylinder can include four hinges 106 and ten joins 110. In some embodiments, the building unit 100 of the quarter cylinder can include five sections 104. In some embodiments, the ten joins 110, when closed, can form five edges of the quarter cylinder (e.g., edge of the three-dimensional hollow building unit 114), and the four hinges 106 can form four edges of the quarter cylinder (e.g., edge of the three-dimensional hollow building unit 114). In some embodiments, the width of the quarter cylinder can be about 10 mm to about 1000 mm. In some embodiments, the length of the quarter cylinder can be about 10 mm to about 1000 mm. In some embodiments, the height of the quarter cylinder can be about 10 mm to about 1000 mm.
In some embodiments, any shape or configuration could be used.
In some embodiments, the toy building unit 100 can be made of a material suitable for method of manufacturing a toy building unit 100 that is capable of folding from a flat position 102 into a three-dimensional hollow position 108 wherein the building unit 100 can include a plurality of sections 104, wherein the plurality of sections 104 can be delineated from and connected to at least one other section 104 with a hinge 106 that is integral to the building unit, a plurality of joins 110 (which are the outer edges of the building unit) outlining the building unit 100, wherein the joins 110 can connect the sections 104 of the building unit 100 forming edges of the closed three-dimensional hollow building unit 108.
In some embodiments, the building unit 100 can be made of a material. In some embodiments, the material can be cardstock, cardboard, bagasse, wood, wood sheeting, particle board, laminate, plastic, plastic sheeting, vellum, vellum paper, rubber, foam sheeting, vinyl sheeting, rubber sheeting, plasticized pulp, pulp, recycled pulp, or any combination thereof. In some embodiments, a pulp can be, for example, paper pulp, bagasse pulp, hemp pulp, bamboo pulp, wood pulp, or any combination thereof. In some embodiments, the building unit 100 can be made of a material that includes a resin. In some embodiments, the resin can be, for example, polyester resin, phenolic resin, alkyd resin, polycarbonate resin, polyamide resin, polyurethane resin, silicone resin, epoxy resin, UV resin, or combinations thereof. In some embodiments, the building unit 100 can be made of a material that includes coatings. In some embodiments, coatings can include wax, plastic, bioplastic, or combinations thereof. In some embodiments, the building material 100 can be made of a material that includes one or more additives. In some embodiments, the building unit 100 can include a laminate of one or more materials. In some embodiments, a laminate can be two or more layers of different materials, often with a plastic being the outer layer, e.g., laminated paper can be a plastic layer bonded to a paper layer, and laminated wood is generally a plastic layer bonded to a wood layer (could be three layers chip board, wood veneer, then plastic). In some embodiments, one or more additives can include resin, coatings, colorants, stabilizers, a laminate, and the like.
In some embodiments, the building unit 100 can include material, or a coating applied therein, that is receptive to a marking. Example markings can include pencil, crayon, chalk, paint, or ink drawing. In some embodiments, the building unit 100 can be configured to be washable or erasable after certain markings are applied. In further embodiments, the building unit 100 can be configured to be resistant to the application of certain markings. In some embodiments, a marking can be applied to the building unit 100 at manufacture. In further embodiments, the applied marking can be invisible until chemically activated. For example, the building unit 100 can include a surface configured to activate normally invisible ink. In another example, the building unit 100 can depict an image, color, or pattern when wet.
Provided herein in some embodiments are methods of manufacturing the toy building unit 100 disclosed herein.
In some embodiments, the toy building unit 100 can be manufactured from a single sheet of material. In some embodiments, the method can include: cutting a building unit 100 from a single sheeting material; forming a plurality of hinges 106; and forming from the edge of a segment of the building unit, a plurality of joins. In some embodiments, the cutting process can be die cutting, laser-cutting, or combinations thereof. In some embodiments, the hinges 106 can be formed by crease scoring the material. In some embodiments, the hinges 106 can be formed by cut scoring the material. In some embodiments, the building unit 100 manufactured by die cutting, laser-cutting, crease scoring, cut scoring, and combinations thereof can be made of cardstock, plastic sheeting, wood sheeting, bagasse sheeting, foam sheeting, particle board, vellum paper, cardboard, paper, vinyl sheeting, rubber sheeting and laminates of any of these materials. In some embodiments, the method can include cutting a plurality of teeth 112 from the edge of a section 104 of the building unit 100. In some embodiments, the method can include a straight edge. In some embodiments, the straight edge can crease score or cut score the building unit 100 to form the hinges 106. In some embodiments, the method can be digital.
In some embodiments, the method of manufacturing a toy building unit 100 can include forming, by a molding process of a material, a building unit that can include a plurality of sections 104, wherein the plurality of sections 104 can be delineated from and connected to at least one other section with a hinge that is integral to the building unit 100; and a plurality of joins 110 along the outer edges of the building unit 100. In some embodiments, the joins 110 can comprise one or more, or a plurality of teeth 112. In some embodiments, the molding process of the material can include injection molding (see e.g., https://en.wikipedia.org/wiki/Injection moulding). Suitable materials for injection molding can include plastic, bioplastic, rubber, or combinations thereof.
In some embodiments, the molding process of material can include wet pressing, dry pressing, transfer molding, thermoforming, or combinations thereof (see e.g., Moulded Pulp Manufacturing: Overview and Prospects for the Process Technology Article in Packaging Technology and Science, February 2017). Suitable materials for wet pressing, dry pressing, transfer molding, thermoforming, or combinations thereof can include paper pulp, bagasse pulp, hemp pulp, bamboo pulp, wood pulp, recycled pulp, or combinations thereof. Suitable materials for wet pressing, dry pressing, transfer molding, thermoforming, or combinations thereof can further include resins, wax, plastic, bioplastic, or combinations thereof.
In some embodiments the method can include a waterproofing step.
In some embodiments the method can be three-dimensional printing.
The figures provided herein illustrate the toy building unit 100 and features thereof according to some embodiments of the present disclosure. The figures show combination with hinges 106 and joins 110, but any combination of joins 110 and hinges 106 can be used. For example, in some non-limiting embodiments, the building unit 100 can include only joins 110 between sections 104.
The compressible designs in
Toy building units with cut hinges and cut teeth may benefit from ease of manufacturing by virtue of being compatible with the installed base of high volume die cutting equipment which is prevalent in the art. For example, in some aspects of the disclosure, a die configured to cut a toy building unit may cut the building unit, joins, hinges and teeth in a single press of a die press machine or in a single pass of a rolling die cutting machine. Similarly, in some aspects of the disclosure, a die configured to cut a building unit may press-form the hinges and cut the building unit, joins and teeth in a single die press or in a single pass of a rolling die cutting machine. In some aspects of the disclosure, a die configured to cut the toy building unit may cut the building unit, joins, hinges and teeth in more than one press of a die press machine or in more than one pass of a rolling die cutting machine. Similarly, in some embodiments, a die configured to cut a building unit may press-form the hinges and cut the building unit, joins and teeth in more than one die press or in more than one pass of a rolling die cutting machine. A wide range of material may be suitable for die cut units, including cardstock, cardboard, rubber, foam sheeting, plastic sheeting, bagasse sheeting, and laminates.
Toy building units having such a structure (e.g., having an integral hinge, interleaving teeth, a consistent single layer of material having a thickness of about 1.5 mm) can be configured to enable small forces (e.g., as would be the case for forces applied by children) to easily transform the unit from a closed 3D to flat 2D net.
The units shown in
In some embodiments, the cuts may aid in allowing the toy building unit 2300 to maintain a consistent and intended shape (e.g., a polyhedron). For example, each face of the toy building unit 2300 can be substantially planar by limiting compressed (i.e., crimped) material in the corners. Further, each edge may maintain a substantially intended angle (e.g., 90° for a cube). Without the cuts, the compressed material would push outward and curve the surfaces. The combination of cuts and interleaving teeth may improve the openability of the folded toy building unit 2300 during play. As a result of the cuts, one or more gaps may exist along the edges of the toy building unit 2300.
Briefly referring to
In some embodiments, the laminate layer 2406 is substantially thinner than the remaining material. For example, the laminate may be between 0.5 mm and 5 mm in thickness. In some embedment's, the laminate can be approximately ⅕th, ⅙th, 1/7th, ⅛th, 1/9th, 1/10th, 1/15th, 1/20th or any value in between, the total thickness of the toy building unit 2400.
In some embodiments, the cuts may aid in allowing the toy building unit 2300 to maintain a consistent and intended shape (e.g., a polyhedron). For example, each face of the toy building unit 2300 can be substantially planar by limiting compressed (i.e., crimped) material in the corners. Further, each edge may maintain a substantially intended angle (e.g., 90° for a cube). Without the cuts, the compressed material would push outward and curve the surfaces. The combination of cuts and interleaving teeth may improve the openability of the folded toy building unit 2300 during play.
In certain embodiments, the cuts are made entirely through the material to the laminate. Alternatively, the cut can be made through only a portion of the material. In either embodiment, the laminate may be configured to provide fully structural integrity for the hinge forming the edge of the toy building unit 2300 (e.g., should the material fail after repeated folds). Cutting through only a portion of the material may be advantageous as it may avoid damaging the laminate during manufacture.
It should be understood, that cutting the toy building unit may weaken the overall strength of the toy building unit, thus making it ineffective as a storage container.
In some aspects of the disclosure, toy figures can be personalized with digital photographs. The toy figures may be used as a component in a toy building set comprising: toy blocks, toy vehicles, or other toy elements to which the toy figures detachably interconnect, or any combination thereof. The assembled toy figures with a connector and base part, or base section, can include a re-attachable photo section or image section which may be personalized by the user using the systems and methods described herein. The connector and base part may be integrated into a single part, may include two or more parts, or may be eliminated. If the connector and base part are eliminated a photo section may comprise a toy figure which may lay flat on a surface. In some aspects of the disclosure, software methods can be used for enabling a user to construct a personalized figure with a section rendered with a digital image selected by the user.
A system of one or more computers and a printer can be configured to perform operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation can cause the system to perform the actions.
One general aspect of the disclosure can include a toy figure including a photo section having a flat element rendered with a digital image, at least one base part, a connector to engage with the photo section and the at least one base part to hold the photo section in a desired position in three-dimensional space, or any combination thereof.
In another aspect a method of producing the toy figure can include printing a digital image on the top surface of image receptive material. An adhesive with a peelable paper backing can be placed on the bottom surface of the image receptive material. A digital image can be adapted by software to scale and to include a fold line. The adapted image can be imprinted on a top surface of the image receptive material and the peelable paper back can be removed from the bottom surface to expose the adhesive. The image receptive material containing the adapted digital image can be folded along a phantom (i.e., not visible) or visible fold line. The exposed adhesive on the bottom surface of the image receptive material can mutually engage on the inside (e.g., bottom surface) of the fold of the image receptive material to form a two-sided photo section. The two-sided photo section can be coupled to a connector which may attach to a base part, and the two-sided photo section can be held with the connector and base part in a desired position in three-dimensional space.
In a further aspect, a method for producing a toy figure can include the user personalizing a toy figure by selecting a digital image from a plurality of stored digital images with a processing device and/or creating with the processing device an adapted image comprising a fold line and a mirror outline image of the selected digital image. The adapted image can be sent to a printing device which can print it on a top surface of image receptive material. The adapted image is folded along a phantom fold line or a visible fold line. The bottom surface of the image receptive material when folded can form an interior, self-adhered layer. The mirror outline image and the digital image may be congruent, overlapping and/or aligned along their respective outside image boarders on opposite outer surfaces of the photo section. The photo section may be joined with a connector and/or base part.
In another aspect a photo section may comprise a complete toy figure which lies flat on a surface.
In other aspects, a connector and base part which hold a photo section may be integrally connected together as a single part.
In other aspects, a connector and base part may be designed to visually appear as an extension of the photo section, such as shoes, legs, or a body.
In other aspects, a connector and base part may be designed to visually appear as a carrier of the photo section, such as a vehicle or animal.
In a further aspect, a method for producing a photo section may include the user selecting a digital photo of a subject's face to include in the adapted image by using a digital photo editing tool, for example a loop outline cropping software tool, to digitally clip the photo of a subject's face from a larger digital photographic image.
In a further aspect, a method for creating a digital photo of a subject's face for use in the adapted image of a photo section may include using facial image recognition software to extract digital images of faces from larger digital photos that include one or many figures.
In a further aspect, in order for the name of a chosen subject to be included as a data label linked to a digital image of a chosen subject, text recognition software may be used to extract names from a larger digital photo from which the digital face of a chosen subject is extracted.
In a further aspect, a method for producing a photo section can include the use of high-resolution instant photo paper for the image receptive material to produce small faces of personalized subjects in small dimensions (e.g., including printed faces with diameters from 2 to 10 mm in diameter), and which can be of sufficient resolution for a user to recognize the subject. Examples of instant cameras and photo printers which print on image receptive material, and which may be capable of producing photo sections with recognizable faces of subjects with diameters between 2 and 10 mm include, but are not limited to, Canon SELPHY photo printers, ZINK thermal printers and FUJI Instax instant cameras.
A further aspect may include physical templates in the form of sheets which may be converted to digital images to be rendered on the photo section. Physical templates may have black and white line drawings for a child to cover. A physical template may have a rectangular outline with a desired aspect ratio. A child may create an artwork in the rectangular outline using various methods (e.g., drawing, painting, coloring). A physical template may be configured to visually pair with a connector or base part.
Example aspect ratios for a physical template can be 2:3 and 1:1 (or square). These may be common aspect ratio for digital images taken with smart phone cameras. The aspect ratio can be 2:3 for 2 inch×3 inch sticker sheets which can be receptive to images printed by thermal printers, including those sold by Canon®, HP® and Epson® which use thermally printable sticker sheets produced by Zink®. In some embodiments, the sticker sheets can be 3.5 inches×4.25 inches. Printable square sticker or label sheets may also readily be available by suppliers, including Avery®.
A physical template may be larger than the photo section on which it is printed, thereby providing an entertaining shrinking effect for a child who personalizes the physical template with a hand coloring or drawing.
An example embodiment of the present invention can be a photo section thermally printed on a 2″×3″ image receptive sheet which can depict an image of a physical template with the same aspect ratio, the physical template having been hand colored, drawn, or painted by a user.
A photo section may be a composite image formed by combining and editing more than one digital image using software methods described herein, or other software methods common in the art of image editing such as those offered by Apple®. Adobe®, Canva®, and Microsoft®. One or more of the digital images selected by a user to be digitally combined into a personalized composite image may be a digital template which frames or provides context relevant to the connector or base part which the photo section may be attached to. For example, a template may be a window frame into which one or more images with heads of particular people may be added. Further to the example, a composite image which uses a window template may be size matched to a base unit which is a toy block.
An embodiment of the present invention may be a photo section with a composite image which can include; a) an image of a physical template manually worked on by the user (e.g., with handiwork such as drawing, coloring, pasting, painting) and/or b) at least one image of the head of a person selected by the user. When such a composite image is digitally composed, printed and formed into a photo section, a user may be delighted by the combination of multiple personalization options and a size-changing effect (e.g., shrinking) due to the physical template potentially being a different size than the photo section on which it is printed.
Digital templates selected by the user to form part of a composite image may have transparent sections which may simplify the creation of a composite image using software methods. Digital templates selected by the user may be a crop tool which may apply a desired outline shape to another image selected by the user.
A photo section which utilizes a digital template may have a face image framed to suit a specific composition, connector or base part, or any combination thereof.
A physical template may have an area or part with a particular outline or shape that may be transformed into a transparency by a software method, automatically or by a user. Such a transparency may be used to frame a digital image of a particular face.
The embodiments described herein as being thermally printed on 2×3 inch sheets may not be limited in size or process. They may be different sized, printed on different sheeting, and with different printers such as desktop printers and professional printers which are common in the art.
In some aspects, the techniques described herein may relate to a toy figure that may include any combination of the following: one or more first portions, each first portion including: a first layer including an image receptive material rendered with a first digital image; a second layer including an adhesive material; and a third layer attached to the first layer by the second layer; one or more second portions, each second portion including: at least one connecting groove to engage with at least one of the one or more first portions to hold the at least one of the one or more first portions in a desired position in three-dimensional space relative to the second portion; and a three-dimensional base part, wherein the three-dimensional base part includes at least one of: shoes, feet, an animal, part of an animal, a vehicle, or a plant base, or any combination thereof.
In some aspects, the techniques described herein may relate to a toy figure, wherein the third layer may include the image receptive material rendered with a second digital image.
In some aspects, the techniques described herein may relate to a toy figure, wherein the one or more first portions can each be formed with a single sheet of the image receptive material that can be folded along a fold line to form the first layer and the third layer of the one or more first portions from the single sheet.
In some aspects, the techniques described herein may relate to a toy figure, wherein the second digital image can be a mirror image of the first digital image.
In some aspects, the techniques described herein may relate to a toy figure, wherein one of the first portions can form a one-part flat toy figure.
In some aspects, the techniques described herein may relate to a toy figure, wherein the at least one connecting groove can include a first member and a second member each having an opposing surface for engaging, through friction or tension, at least one of the one or more first portions.
In some aspects, the techniques described herein may relate to a toy figure, wherein the at least one connecting groove can include a mating section to removably engage with the three-dimensional base part.
In some aspects, the techniques described herein may relate to a toy figure, wherein the mating section can include a recess to engage a stud to removably engage the at least one connecting groove to the three-dimensional base part.
In some aspects, the techniques described herein may relate to a toy figure, wherein the mating section can include a ferromagnetic element within the at least one connecting groove, to form a connection with a magnet in a separate part.
In some aspects, the techniques described herein may relate to a toy figure, wherein the image receptive material can include at least one of: Zink stickers, Zink paper, instant film paper, thermal printer paper, plain paper, sticker paper, vinyl sticker paper, label paper, glossy paper, a laminate covering, and photo paper.
In some aspects, the techniques described herein may relate to a toy figure, wherein the digital image can include a digitized photo of a hand drawn illustration and a digital photograph of a face.
In some aspects, the techniques described herein may relate to a method of producing a toy figure that can include any of the following: imprinting a digital image on a top surface of the image receptive material, wherein the image receptive material can have an adhesive covered by a peelable paper back on a bottom surface; and wherein the image receptive material can have an area less than 64 square centimeters; removing the peelable paper back from the bottom surface to expose the adhesive; manually folding the image receptive material containing the digital image along a fold line that bisects the image receptive material into two equal parts, a first layer and a second layer; mutually engaging the exposed adhesive on the bottom surface of the first layer and the second layer to form a two-sided first portion; and pairing the first portion with a second portion including: at least one connecting groove which can be configured to engage with the first portion to hold the first portion in a desired position in three-dimensional space relative to the second portion; and a three-dimensional base part, wherein the three-dimensional base part can include at least one of: shoes, feet, an animal, an animal part, a vehicle, or a plant base that can be configured to be perceived by a user as a visual extension of the digital image.
In some aspects, the techniques described herein may relate to a method, wherein imprinting the digital image on the top surface of the image receptive material can include imprinting the digital image on the image receptive material on one side of the fold line and/or imprinting a mirror outline image of the digital image on the image receptive material on another side of the fold line such that when the image receptive material is folded along the fold line, the two images align and overlap.
In some aspects, the techniques described herein may relate to a method wherein the connecting groove can include two opposing surfaces configured to receive and/or engage the first portion between the two opposing surfaces.
In some aspects, the techniques described herein may relate to a method further including any combination of the following: scaling the digital image to a pre-determined size; creating with a processing device a mirror outline image of the digital image; and printing the digital image and the mirror outline image on separate sides of the fold line such that the outlines of the two images can align and/or overlap when the adhesive layer is exposed, and the image receptive material can be folded along the fold line to form the first portion.
In some aspects, the techniques described herein may relate to a method, which can further include: integrating a recess in the connecting groove configured to interlock via friction with a stud of diameter 4.8 mm; and
In some aspects, the techniques described herein may relate to a method wherein the digital image can include at least one of: a digitized drawing, a digitized illustration, or a digital photograph.
In some aspects, the techniques described herein may relate to a method further including: modifying the digital image based on one or more source digital images; and/or storing the digital image in response to the modification.
In some aspects, the techniques described herein may relate to a method, wherein imprinting the digital image can include printing the digital image with a printing device that includes at least one of: a Zink printer, a Zink sticker printer, an instant camera, a Zink camera, a thermal printer, a laser printer, an ink jet printer, and a dot-matrix printer.
In some aspects, the techniques described herein may relate to a part to hold a toy figure, the part including at least one of: a recess on a bottom side configured to interlock with and cover the top of a cylindrical stud of diameter 4.8 mm; and a thin, flat blade protruding lengthwise from a top side, the blade less than 75 mm long and less than 10 mm wide; wherein the bottom side of the part can have a footprint less than or equal to 9.5 mm long and 9.5 mm wide.
Referring to
Referring to
Alternately the images 2602, 2602c, 2603 and 2603c may be printed on image receptive material 2606 without the fold line but can be equally spaced from a non-visible line that bisects image receptive material 2606. The fold line may be placed at a middle of sheet lengthwise or width wise so that opposite corners of the sheet can align when the sheet is folded on the fold line.
The image receptive material 2606 can have an adhesive backing 2608 with a removable film protective cover 2610 extending over the adhesive backing. Alternately, adhesive may be physically applied by a user or device to the image receptive material 2606.
Referring to
The process for producing a toy figure may include selecting a template. The template may be a digital template or a physical template. A digital template may be selected from a series of digital image files stored either locally or remotely (e.g., a website). A physical template may be selected from a collection of physical templates (e.g., a booklet). The digital template may be printed into a physical template and manipulated as described herein. A physical template may include a line drawing. A physical template may include a marking or fiducial (e.g., a QR or bar code) which may identify the template and/or provide location information associated with the template to a computer system, when the template is captured via a camera or scanner. A physical template captured by a camera or scanner may become a digital template and manipulated as described herein.
The template may be customized by a user. A physical template may be customized using ink, pencils, crayon, paint, glue, glued/adhered on elements (e.g., other images, glitter, stickers, etc.). A digital template may be customized via software configured for digital image manipulation (e.g., Canva® or Adobe Illustrator®).
A digital template may include one or more regions configured for inserting a photograph. The one or more regions may be configured as a transparent region. The photograph may be digital placed in reference to the digital template with only the portions overlapping the transparent region being visible. Alternatively, the digital template may be used in conjunction with a digital photography application. For example, a user may be prompted to take a photo using a mobile phone, tablet, or computer camera, where the digital template overlays the photo such that only the transparent region depicts the camera's view through the digital template. On taking the photo, the combined view of the camera and digital template may be merged into a single image. Multiple photos may be merged with multiple regions of a template in a similar manner.
A digital template may include one or more outlined or cropped regions. For example, a digital template may be configured such that any customization outside an outer border can be cropped from the image. A specific crop outline may include cropping the specific outline of, for example, a face, a head, body, or thing which separates the head, body, or thing from the background of an image. A crop outline template may be used to adapt a source image to have a predetermined outline shape.
In block 2702, an adhesive can be applied to the one side of an image receptive material (e.g., plain paper, cardboard, construction paper, matt paper, a Zink sticker, sticker paper, vinyl sticker paper, label paper, glossy paper, a laminate covering, or photo paper, or any combination thereof) and a removable backing layer may then be applied to cover the adhesive. The image receptive material may be receptive to one or more inputs that aid in the creation of the image such as heat (e.g., Zink) or ink. The image receptive material may include film (e.g., INSTAX®, POLOARIOD® or SELPHY® material) that can be photo receptive.
In block 2703, a determination can be made on how many sides of the image receptive material the digital image will be imprinted. In response to a determination that the digital image is to be imprinted on one side, in block 2704, the system can create and print the digital image on the image receptive material at a preselected size (e.g., by the software based on a known template size or by the user) having a desired output dimension without a fold line. Once the one-sided digital image is printed, the printed image may be trimmed in block 2710 to form a photo section.
If the digital image is to be imprinted on two sides of the toy figure, in block 2705, the system can create and print the digital image and a second digital image. The second image may be a mirror image of the original digital image or a new digital image that is not a mirror copy (e.g., a blank image, a default textual, graphical, photographical, or illustrative pattern, a unique digital image based on the same or a mirror template of the original digital image, or a unique digital image cropped to a mirrored template of the original digital image, or any combination thereof) on the image receptive material. In some embodiments, a user may select a size for the digital image with a desired output dimension and a fold line to create the photo section. In further embodiments, the desired output dimensions may be selected from one or more predetermined dimensions. The image and copy may be separated when printed by a uniformly colored (e.g., white) or textured space (e.g., a pattern of stars) with the fold line floating in the uniform space. The image can be printed on the top surface of a first section of the image receptive material and the second image can be printed on a second section of the image receptive material. In some embodiments the fold may be a distance from the images to be able to trim the fold (e.g., with a flat connector the fold may be trimmed off).
In block 2706, a determination can be made as to the type of connector. An example of a connector which has a groove comprising two opposing flat surfaces to engage a photo section (referred to herein as a grooved section or grooved connector).
If a determination can be made that the connector is grooved, in block 2708, the adhesive back, if present, can be removed. With the adhesive exposed, the digital image may then be folded along the fold line to mutually engage a bottom surface of the image receptive material below the first image with the bottom surface of the image receptive material located below the second image the digital image. This folding can result in the formation of a photo section flat element with the respective outside image boarders of the digital images aligning. In some embodiments, the photo section flat element may be, for example, trimmed (e.g., with scissors) or perforated and punched out along the outside boarder of the images in block 2710.
In block 2712 the photo section may be coupled to the grooved section.
If a determination can be made that the connector includes a double-sided flat surface (also referred to herein as a flat connector), in block 2714 the adhesive back can be removed, the bottom surface adhered to the flat surface and the digital image can be folded in half over the flat surface. The digital image may cover the flat element to form a photo section flat element which includes a flat connector adhered between its two sides and the photo section can be trimmed in block 2716.
In block 2718 the connector may be engaged with a base part to form the three-dimensional toy figure.
Portions of the processes described herein may be performed by the manufacturer or end user. For example, in some embodiments, the manufacturer may provide a template, either physically or digitally, to the user, which the user can customize and can return to the manufacturer for printing. A completed image section and base section may then be provided to the user. In other embodiments, the user may use software to locally produce portions of the toy figurine. For example, the user may print the images and form the image section and/or use a 3D printer to produce the base section.
Processing device 2804 can execute instructions stored in memory 2812, and in response thereto, can process signals from hardware 2806. Hardware 2806 may include I/O device 2838 having network and communication circuitry for communicating with a network or a printer controller for communicating with printer 2840. Input device 2836 can receive inputs from a user of the computing device through one or more input devices including any combination of: a keyboard, mouse, track pad, microphone, audio input device, video input device, or touch screen display. Display device 2834 may include an LED (Light emitting diode), LCD (Liquid crystal display), CRT (cathode ray tube) or any type of display device.
Memory 2812 may include volatile and non-volatile memory, removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules or other data. Such memory 2812 includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, RAID storage systems, or any other medium (including a non-transitory computer readable storage medium) which can be used to store the desired information, and which can be accessed by a computer system. The storage may be local or cloud-based.
Modules stored in memory 2812 of the computing device 2800 may include an operating system 2814 having an I/O controller, a database 2830, and application 2820. The operating system 2814 may be used by applications 2820 to operate the computing device 2800. I/O device 2838 (also referred to as a controller) may provide drivers for computing device 2800 to communicate with hardware 2806 or printer 2840. Database 2830 may include digitized drawings, digitized illustrations, digital photographs, prestored images, prestored material (paper) sizes, alpha numeric text, and other parameters such as personal computing device operating parameters and configurations.
The process 2900 may performed by processing device 304 when executing the software instructions in application 2820, and specifically the Figure Production Software Application 2822 shown.
In the process 2900, the computing device 2800 (
In block 2904, the user may select the images from the database 2830, the connector type that will hold the printed image, and the final size of the image. Alternatively, one or more of these inputs may be predetermined. For example, the printer may be configured to print a predetermined size. In another example, choosing a specific connector type and/or base part may automatically provide an optimal image size.
In block 2906, the image can be formatted, aligned, and sized for the selected connector and/or base part.
In block 2908, the formatted image can be aligned for printing, and at least a partial mirror of the selected digital image can be created. The partial mirror image can be created with an outside boarder such that when printed the outside boarder of the formatted image can align with the outside boarder of the partial mirror image. In some embodiments, a different image may be substituted for the mirror image, that may be formatted so the boarders at of the formatted imaged and the substituted image align. In some embodiments the partial mirror image may be a full mirror image.
In block 2910 the aligned image and the mirror image (or the substitute image) along with an optional fold line that bisects the two images can be sent to a printer (e.g., printer 340) to be printed on a top surface of the image receptive material. The printer can print the digital image on a top surface of a first section of an image receptive material and can print the mirror image on a top surface of a second section of the image receptive material, and optionally can print a fold line bisecting the two images. In some embodiments, the fold line may be prestressed and/or perforated to guide and/or ease the folding process.
In
Referring to
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Referring to
In some embodiments, the interface 3302 includes one or more holes configured to affix the external element. For example, the holes can be space and sized to receive an array of LEGO® studs.
In other embodiments, two toy building units 3310 can be joined via a rod inserted through an interface 3302 on each of the toy building units 3310. In certain embodiments, the rod can be securely connected to the interface 3302 via compression and/or friction with the material of the toy building unit 3310. In further embodiments, the rod can be rod can be securely connected to the interface 3302 with a clip, nut, or gasket (e.g., a rubber band).
In alternative embodiments, the interface 3302 can include other methods of affixing two toy building units 3310. For example, the interface can include a pre-applied adhesive accessible by peeling away a section of adhesive liner. In another example, the interface 3302 can include hook and loop strips. In a third example, the interface 3302 can include one or more ferromagnetic materials.
In certain embodiments, the toy building unit 3340 can be pre-configured to connect to specific external elements. For example, as depicted in
In some embodiments, the toy building unit 3340 can be personalized by the user. Personalization can include applying standard or custom images 3342. Custom images can be developed such as described in reference to
In some embodiments, the extracted images 3410 can be further processed as depicted in
Although the examples discussed herein refer to images of people, other images may also be processed similarly. In some embodiments, images of fictional characters, animals, and/or objects can also be processed. Machine learning algorithms may require distinct training to accept alternative imagery.
An embodiment provides a toy building set that can include a building unit which is capable of folding from a flat position into a three-dimensional hollow position; the building unit can include a plurality of sections, wherein the plurality of sections can be delineated from and connected to at least one other section with a hinge that is integral to the building unit; a plurality of joins (which can be the outer edges of the building unit) outlining the building unit, wherein the joins can connect the sections of the building unit forming edges of the closed three-dimensional hollow building unit; and a closed position.
In some embodiments, the building unit can be cardboard. In some embodiments, the building unit can be bagasse. In some embodiments, the building unit can be wood. In some embodiments, the building unit can be laminate. In some embodiments, the building unit can be vellum. In some embodiments, the building unit can be rubber. In some embodiments, the building unit can be plasticized pulp. In some embodiments, the building unit can be a domed cuboid unit. In some embodiments, the domed cuboid unit can include five hinge and fourteen joins. In some embodiments, the fourteen joins, when closed, can form seven edges of the domed cuboid unit; and the five hinges can form five edges of the domed cuboid unit. In some embodiments, the building unit can be a half cylinder. In some embodiments, the half cylinder can include three hinge and six joins. In some embodiments, the six joins, when closed, can form three edges of the half cylinder; and the three hinges can form three edges of the half cylinder. In some embodiments, the building unit can be a quarter cylinder. In some embodiments, the quarter cylinder can include four hinge and ten joins. In some embodiments, the ten joins, when closed, can form five edges of the quarter cylinder; and the four hinges can form four edges of the quarter cylinder. In some embodiments, the closed position can include a flat surface created by a final closure. In some embodiments, the building unit can be laminated.
Another embodiment provides a method of manufacturing a toy building set, the method can include: cutting a building unit from a single sheeting material; forming, by a straight edge, a plurality of hinges whereby pressing the straight edge into the sheeting material forms the hinges; and forming, by cutting a plurality of joins.
In some embodiments, the building unit can be capable of folding from a flat position into a three-dimensional hollow position with the friction of connected joins. In some embodiments, the straight edge can crease score or cut score, the building unit to form the hinges. In some embodiments, the plurality of hinges can appear as a groove on one side of the building unit and a ridge on the opposite side of the building unit. In some embodiments, cutting can be die cutting, blade cutting, laser cutting, or combinations thereof. In some embodiments, the sheeting material can be cardstock, cardboard, plastic sheeting, bagasse sheeting, wood sheeting, pulp sheeting, plasticized pulp sheeting, laminates, and combinations thereof.
Another embodiment can provide a method of manufacturing a toy building set, the method can include: forming, by a molding process of a material, a building unit comprising: a plurality of sections, wherein the plurality of sections are delineated from and connected to at least one other section with a hinge that is integral to the building unit; and a plurality of joins along the outer edges of the building unit, wherein each join comprises a plurality of teeth.
In some embodiments, the building unit can be capable of folding from a flat position into a three-dimensional hollow position with the friction of connected joins. In some embodiments, the molding process of a material can be injection molding. In some embodiments, the material can be a plastic, bioplastic, rubber, or combinations thereof. In some embodiments, the molding process of a material can be wet pressing, dry pressing, transfer molding, thermoforming, or combinations thereof. In some embodiments, the material can be paper pulp, bagasse pulp, hemp pulp, bamboo pulp, wood pulp, recycled pulp or combinations thereof. In some embodiments, the material can further comprise resins, wax, plastic, bioplastic, or combinations thereof.
As will be appreciated, the building unit of a toy building set described herein can afford advantages, including, but not limited to:
In a first aspect, a building unit of a toy building set is provided. The building unit can comprise a sheet of a material that defines a net of a polyhedron, the sheet having a plurality of sections, each section being connected to another section with a hinge. The building unit can be configured to fold at the hinges from a flat configuration into a polyhedron with a hollow interior. The building unit can also comprise a plurality of joins on outer edges of the building unit, each join comprising one or more teeth configured to interleave with teeth of another join and releasably connect the sections of the building unit to form edges of the polyhedron. The sections, hinges and joins can all be provided on one piece of the same material.
Toy elements can be provided in the form of a sheet of a material that can be folded by users (including children) into a three-dimensional polyhedron. Such toy elements can provide a user with a tactile learning experience gained during the formation of a three-dimensional structure from a flat structure and conversely, during the reformation of the flat structure, and during repetitions of the transformations. The product may subsequently be used in further play, both on its own and in combination with other toy elements disclosed herein.
In some embodiments, at least a portion of the hinges may comprise a groove on one surface of the building unit in the flat position and a ridge(s) on an opposite surface of the building unit in the flat position. Such a hinge structure may enable users (particularly children) to perform the necessary folding actions more easily. In some aspects of the disclosure, different modifications can be provided for creating hinges in a single piece. For example, they can be bent to different degrees and/or have a composite material with different layers.
Alternatively, in some embodiments, each hinge may comprise a groove on one surface of the building unit in the flat position and/or no feature or a groove on an opposite surface of the building unit in the flat position. In some embodiment, a portion of the hinges may comprise a groove on two opposing sides of the building unit in the flat position. A groove which comprises a hinge structure may be formed by molding, cutting or applying pressure to the material. For example, in molded plastic, there can be a groove on both sides. As another example, in cut sheeting, there can be a groove on one side and nothing on the other side. Such a hinge structure may not only enable children to perform the necessary folding actions more easily, but may be easier to form in the material and provide for a more simple configuration. In some embodiments, each hinge may comprise a partial cut through the sheet of material. Several example hinge structures will be described in further detail below.
In some embodiments, the teeth of connected joins may be configured to interleave to form a closed edge of the building unit, with friction between the surfaces of interleaved teeth holding the building unit together in the closed position. In such embodiments, the friction fit edge may be configured to unpair by a pulling apart one or more interleaved teeth, enabling a user to readily close, open, and flatten the building unit. In some embodiments, unpairing a friction fit edge may be easier to perform by applying a finger pull, or other force, on particular teeth or portions of the unit. In some embodiments, indicia, physical features or other marking on the building unit, or any combination thereof, may be provided in order to indicate a join opposite a hinge on one or more of the sections.
In some embodiments, the joins may comprise curved, angled, or straight teeth. In some embodiments, the joins may comprise teeth having one or more compressible projections. For example, at least one tooth may be configured to compress or deform in the closed position, such a deformation increasing the friction holding an edge of the building unit together and hence providing for a more secure closure.
In some embodiments, a gap or edge adapted receive a user's fingertip may be provided in at least one section (e.g. in the form of a gap between interleaved teeth of a join, typically the join opposite the hinge of a given section), in order to make it easier for the user to break the friction fit and to reduce the likelihood of damage occurring to the teeth during repeated opening and closing of the building unit. In some embodiments, unpairing a friction fit edge may be easier to perform by applying a finger pull, or other force, on particular teeth or portions of the building unit.
In some embodiments, at least one outer surface of the polyhedron may be receptive to hand-coloring with ink, pencil, crayon, chalk or watercolor, or any combination thereof. Enabling a user to personalize the building unit however they like is expected to even further increase the available play opportunities.
In some embodiments, the building unit may comprise (or be formed of) cardstock, cardboard, bagasse, wood, laminate, plastic, vellum, rubber, foam, plasticized pulp, or pulp, or any combination thereof.
In some embodiments, one or more of the sections of the building unit may have a dimension that is N×8 mm, where N is a whole number. In some embodiments, one or more of the sections of the building unit may have a dimension that is N×8 mm plus or minus V, where V is a small variance (e.g., less than 2 mm). Building units having such a size may be compatible with other toy systems, which can enable yet more play opportunities as the building units can be co-mingled with elements of other toy systems.
In another aspect, a building unit of a toy building set can be provided. The building unit can comprise:
In some embodiments, sides of teeth which may be configured to engage in friction fit can be configured with design overlap which can cause the sides to compress or deform in the closed position.
In some embodiments, the building unit (in the flat position) can have an exterior surface, an interior surface, and an outer edge; wherein the exterior surface can be visible on the exterior of the building unit in the closed position; wherein the exterior surface can be a material receptive to a sticker or a pencil, crayon or ink drawing.
Additional features and embodiments of some aspects of the disclosure may be as described herein in the context of other aspects of the disclosure.
Additional features and advantages of the various aspects of the toy elements, connectors and additional components in the disclosed toy systems will be described below in the context of specific embodiments. It is to be appreciated, however, that such additional features may have a more general applicability than that described in the context of these specific embodiments.
While various embodiments have been described above, it should be understood that they have been presented by way of example and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope. In fact, after reading the above description, it will be apparent to one skilled in the relevant art(s) how to implement alternative embodiments. Thus, the present embodiments should not be limited by any of the above-described embodiments.
In addition, it should be understood that any figures which highlight the functionality and advantages are presented for example purposes only. The disclosed methodology and system are each sufficiently flexible and configurable such that they may be utilized in ways other than that shown. In particular, the elements of any flowchart or process figures may be performed in any order and any element of any figures may be optional.
Although the term “at least one” may often be used in the specification, claims and drawings, the terms “a”, “an”, “the”, “said”, etc. also signify “at least one” or “the at least one” in the specification, claims and drawings. The terms “including” and “comprising” and any similar terms should be interpreted as “including, but not limited to” in the specification, claims and drawings.
In the claims which follow and in the preceding description of the embodiments of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
It is to be understood that any prior art publication referred to herein does not constitute an admission that the publication forms part of the common general knowledge in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202490283 | Sep 2024 | AU | national |
The present application is a continuation-in-part of U.S. patent application Ser. No. 18/066,658 filed Dec. 15, 2022, which is a continuation-in-part of International Patent Application No. PCT/AU2022/051358 filed Nov. 14, 2022, which claims priority to U.S. patent application Ser. No. 17/527,884 filed Nov. 16, 2021. This application also claims priority to Australian Application No. 202490283 filed Sep. 9, 2024. The present application is also related to U.S. patent application Ser. No. 18/067,401 filed Dec. 16, 2022. All of the aforementioned applications are herein incorporated by reference in their entities.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17527884 | Nov 2021 | US |
| Child | PCT/AU2022/051358 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18066658 | Dec 2022 | US |
| Child | 18829015 | US | |
| Parent | PCT/AU2022/051358 | Nov 2022 | WO |
| Child | 18066658 | US |
