US20230390662A1

US20230390662A1 - Electrically Conductive Building Blocks With Anti-Symmetric Contact Mechanisms

Info

Publication number: US20230390662A1
Application number: US18/032,929
Authority: US
Inventors: Boaz Almog; Nadav MANSDORF; Eran OREN
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-10-25
Filing date: 2021-10-24
Publication date: 2023-12-07
Also published as: WO2022085010A1; EP4232176A4; EP4232176A1

Abstract

The invention herein discloses a system including building blocks intended for educational, amusement or functional use of assembling into mechanical and electro-mechanical constructions. The building blocks are electrically conductive and have an electrical connector with an asymmetry property around one of the main, or natural, assembly planes. The asymmetric properties allow the connector to maintain high electrical conductance when assembled near an adjacent building block, without harming the building blocks physically and without requiring complex assembly rules and restrictions. The system can present rotational symmetry of 180 degrees, and can present elastic properties or magnetic properties to further increase the conductivity and durability of the connectors.

Description

FIELD OF THE INVENTION

The present invention relates to the field of toys, hobbies, educational aids and home tools, and more particularly, yet not exclusively relates to building blocks allowing a user to build models for decorative, educational, amusement, practical or other purposes.

BACKGROUND OF THE INVENTION

Providing building blocks for design and assembly by individuals or groups has been known for many decades as an activity carrying the potential to encourage imagination, creativity, technical skills, practical knowledge, group dynamics and stress relief. Out of a variety of common hobbies and past-time activities, using existing building blocks to create a de-novo construction or follow instruction to create some desired one, has shown to be both useful and enjoyable. While in the past, such building blocks were generally confined to mechanical or electro-mechanical disciplines (construction and in some cases electric motors), market demand and innovation has led to implementation of more sophisticated tools that allow the construction of electrical circuitry and extended functionality, even when performed by hobbyists and non-specialists. As a result, a need has arisen for the combination of mechanical building blocks with electrical conductivity, in such a way that does not hamper the mechanical functionality and the user experience.
A variety of solutions were shown in the art for the above-stated task, whereas, it will be shown hereafter that all solutions in the art show some significant limitations. US20110143629 has shown the use of interconnectable building blocks with at least some conductive surfaces for the purpose of building electrically connected circuits. The connection, being of a snap-in type along the intuitively vertical direction is intended for stacking electrically conductive paths rather than implementing them in all 3 dimensions (namely sideways in addition to up and down).
Further to this, U.S. Pat. No. 9,914,065B2 has shown a solution to provide a sideways connection by introducing a spring-like arm allowing for the pressure exertion between two adjacent blocks, even in such a scenario in which the spring arm is not facing another spring arm, but a regular building block wall. In such a case, the spring arm is farther away the desired connection point, and thus the required displacement is higher and potentially achieved pressure is lower. In the configuration disclosed in said patent publication, the spring arm exerts a sideways as well as an upwards pressure that causes both extended wear-and-tear on the spring itself, other springs, the walls and other components, thus promoting fracture and reducing the building blocks' robustness. Furthermore, the upwards force component causes the stacking and connection actions to become more difficult and might harm the building blocks' functionality and user experience.
Further to above-stated disclosure of patent U.S. Pat. No. 9,914,065B2, it shows the use of designated parts of the building blocks when covered with additional materials, referred to as ‘pads’. Said pads are introduced to allow the pressure from the spring-arms to be securely connected to specific, and pre-designated parts of the building blocks, thus allowing the galvanic connection between them. However, not only does the pad introduction incur additional cost, it hampers the use of the building blocks, as it limits the design and implementation to specific directions and configurations. It does not address the need to connect the building blocks when no pad is present, (spring to wall connection) or when no spring is present (pad to pad or pad to wall). This solution thus limits both the system's durability as well as its functionality.
U.S. Pat. No. 8,371,894B1 shows a connection mechanism of toy boy building blocks intended for use with illumination from the flowing electrical power. This patent discloses a coupler element based on a plug-and-socket mechanism to connect blocks sideways. While it can provide a strong coupling mechanism, it limits the usability and incurs additional manufacturing costs due to the mechanism's complex shape.
Patent KR100946794B1 teaches the use a magnetic connection mechanism for light emitting building blocks by providing a connection force between electrodes on two different blocks. The blocks can be stacked on top of each other or sideways and be made in different shapes, but the price of the magnetic electrodes is high.
U.S. Pat. No. 10,653,973B2 teaches a plurality of stackable building blocks with internal electronics and a socket connection mechanism embedded into the stacking connector. The connector mechanism including concentric pin and ring configuration. The connection is only meant for specific blocks to reach a power supply and not for an entire creative assembly that allows connection regardless of structure.
Patents US20180145448A1, EP2217341B1 show connectors to securely hold electrical connection including for data transfer or power supply, whereas the connector in use is provided as a unique connector rather than an integrated part of the building blocks. While the connectors allow the connection of cables or wires to a construction made of mechanical building blocks, it only provides partial functionality to the construction as a whole.
There is thus a need to improve the connectivity, durability and the applicability of building blocks to allow the functional, and enjoyable use as a creative, educational or hobby utility.

SUMMARY OF THE INVENTION

The present invention shows a plurality of inter-connected building blocks with galvanic and mechanical properties that allow the creation of electrical circuitry. Said building blocks, as a stand alone component, or when combined or integrated with additional equipment, component, electrical devices, communication devices and others, form a system intended for use for amusement, educational, practical or other purposes.
To negate the drawbacks of abovementioned art, the current invention shows a plurality of solutions for the implementation of electrically conductive building blocks, maintaining the desired properties of stackable and connectable blocks, while providing with the robust, repeatable and durable galvanic connectivity.
In some embodiments, at least one asymmetric is introduced to the shape, galvanic properties, elastic properties or any combination thereof. Such an asymmetry typically allows for the connection to fit on both sides of a building block by preventing overpressure on the physical contact point.
In its preferred embodiment, and without any limitation to the generalization and scope of the invention, the invention herein discloses an asymmetric lateral connection mechanism that allows for the usage of small distances separating the building blocks to serve as a volume for galvanic connection without introducing high pressure that might harm the user experience when trying to assemble building blocks, and without the requirement to stack them from a specific side, with additional materials or to perform an additional action for the connection to form. The asymmetry is typically introduced around the plane defined by a horizontal line crossing the center of gravity or center of volume of the building block when observed from a top view, defined by the direction of stacking of the building blocks one on the other or on a base board.
The introduced asymmetry is schematically visualized for example in FIG. 1 , where the sides are covered with protrusions, depressions, indentations, plugs, sockets, slits, apertures or any other shape or additional component intended to leave a planar wall to create a galvanic connection. The asymmetry thus causes the distance protruded and indented from the wall plane to the contact point to be lower than would have been in a symmetrical configuration. Furthermore, the asymmetry tends to exert forces in a tilted plane with reference to above described plane, and thus induce structural integrity and prevent detrimental effects to the building blocks themselves or to the construction made thereof.
In some embodiments, the building blocks are made to be electrically conductive by the introduction of a metallic surface coating, metallic connectors, conductive polymers coating, conductive polymer block material, metal block material, internal conductive parts such as an internal conductive core or others.
In some embodiments, the tactile or connectivity properties of the building blocks are enhanced with springs, spring-like arms, elastic materials, shapes intended to bend or any other property allowing for the distance between the intended galvanic contact point to the wall plane to change with pressure or force.
In some embodiments a magnetic component is introduced as a permanent magnet, ferromagnetic material, paramagnetic material or a conductive coil, typically causing a spontaneous or a triggered force to connect two or more conductive sides.
In some embodiments, a mechanical mechanism is implemented to allow the connect or disconnect of two or more sides of the conductive parts of a building block. Such mechanisms can be rotary (screw and tap), linear, button based or others.

BRIEF DESCRIPTION OF THE FIGURES

The figures attached hereto are representative of some of the embodiments described in the text and are intended for the purpose of explanation and clarification for a reader or observer with relevant skills in the art. The figures are intended to illustrate and exemplify and do not hold the full structural detail described herein.

In the Figures:

FIG. 1 constitutes a schematic top perspective view of a block with reflection asymmetric connections. The block shows a 180 degrees rotational symmetry

FIG. 2 constitutes a schematic top view of two building blocks with reflection asymmetric connections showing the protrusion creating a contact point when opposed to a wall

FIG. 3 constitutes a schematic top view of two building blocks with reflection asymmetric connections showing the protrusion creating a contact point when opposed another protrusion

FIG. 4 constitutes a schematic top perspective view of a block with reflection asymmetric connections from all lateral sides

FIG. 5 constitutes a schematic top view representation of multiple building blocks of different shapes connected together in some array exemplifying the construction process

FIG. 6 constitutes a schematic bottom isometric view of potential wall thinning for added flexibility and durability.

FIG. 7 constitutes a schematic top view showing an embodiment with asymmetric protrusions marked against the symmetry plane

FIG. 8 constitutes a schematic cross sectional top isometric view showing a close-up presentation of the connection mechanism in FIG. 7

FIG. 9A shows a representation of a common connection mechanism in the state of the art exerting forces horizontally due to the symmetric structure

FIG. 9B shows a representation of an asymmetric connection mechanism exerting forces in diagonal directions, tilted in relation to the wall plane

FIG. 10 constitutes a different embodiment of an asymmetric mechanism showing jagged connectors

FIG. 11 constitutes an isometric view of an embodiment with jagged connectors and a slit with a thinner wall for increased flexibility.

FIG. 12 constitutes an isometric view of an embodiment using a combination of slits and hemispherical bumps

FIG. 13 constitutes an isometric view of an embodiment using a flexible protrusion.

FIG. 14 shows an electrical measurement of one embodiment in different configuration achieving sufficiently low electrical conductivity for integrating circuits.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

In the following detailed description, specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components, modules, units and/or circuits have not been described in detail so as not to obscure the invention. Some features that are presented with respect to one embodiment are not repeatedly presented for another. The detailed description makes references to the figures where similar numbers refer to similar components.
In its preferred embodiment, the invention herein shows the use of at least one asymmetric property in a building block, typically used as a toy, to allow the galvanic (electrical) connection of adjacent blocks for such purposes as building electric circuits and electromechanical systems with said blocks. The galvanic connection is based in its essence on two aspects:

- 1. The building block, or a part of it is electrically conductive, thus allows electricity flow when connected in a circuit;
- 2. Some protrusion from the building block can touch and close an electric circuit with additional blocks of the same type, of different types or with wires, electric components or other components.

The combination of said aspects allows the construction of mechanisms with embedded electronics, motors, illumination, sensors, communications or other electrically actuated components.
Building blocks of the stackable and connectable types are typically stacked in some vertical direction in such a way that the bottom of a block is firmly secured to another block or a base plate underneath it. Said blocks are typically manufactured with an engineered gap in the lateral directions between them when assembled, in order to prevent the need of high force exertion during assembly and in order to increase durability and prolong their life span. Thus, even in case of a fully conductive building block, in a typical assembly, the air gap between two blocks located adjacently in the lateral direction will prevent a short-circuit between them and the flow of electricity.
While prior art has shown the use of protrusions, sockets and plugs to connect such building blocks, the invention herein presents the use of a connection mechanism with at least one asymmetric aspect around one of the axes or planes defining a building block.
In the preferred embodiment, a building block has a rectangular shape in the top view (projection along stacking direction), defined by 4 walls. The line connecting the centers of each two opposite walls in such a configuration defines a symmetry plane when extruded along the bottom to top direction. The invention herein shows the use of an asymmetric configuration of protrusions, poles, buttons, bulges, slits, sockets, crevices, apertures, holes or other shapes and elements in a way that is typically set around the above-defined plane. For example, for illustrative purposes only, FIG. 1 shows a protruding and inward converging mechanism (101) that forms an electric connection with a sufficiently low electric resistance and impedance with such values as 0.0001-1 Ohms per a 2-block connection, as FIG. 2 schematically shows the connection when it is formed between the protrusion of the connector element (101) and a standard wall (102) in an adjacent building block. FIG. 3 shows the same schematic building blocks when forming a connection between the connector protrusion (101) and another connector protrusion.
In the preferred embodiment, the building blocks show some asymmetry along at least one line or plane, that is typically an anti-symmetric reflection in order to allow both the direct fitting to a similar connector in another building block, as well as to properly fit a plane wall of a building block without such a connector. In both cases, the asymmetry prevents the application of overpressure that can cause a misfit of components or an increased wear. It is thus emphasized, yet is only given as an example that in some embodiments, the asymmetry is around a central point or line, which can be through a building block wall's center or the center in at least one projection of said wall.
In some embodiments the electrical resistance of a single block including the connections can be in the range of 0.0001-0.001 as can be seen as a general example in a 4-probe measurement of a 2-block connection in FIG. 14 . In other embodiments, the electrical resistance can be in a different range such as 0.001-1 Ohms, or lower. In other embodiments, some or all blocks can have semi-conductor properties or allow for super-conductive properties.
In some embodiments, the protrusions, indentations or any other connector types are located on some or any of the possible walls. For example, FIG. 4 shows a schematic building block of a rectangular shape with similar connectors on all four lateral sides.
In other embodiments, at least one asymmetry is introduced in the connector mechanism, around some plane which can be the horizontal plane parallel to the stacking, a plane that is offset from the center of a wall, multiple planes with different asymmetries of different types, or tilted planes with reference to the horizontal plane. The asymmetry can be of an anti-symmetric type, fully asymmetric, include symmetric components, or any combination of said configurations.
Building blocks can take multiple shapes or forms, and while in some presented embodiments, they are rectangular in shape or can be described as a set of connected rectangles, in other embodiments, the building blocks can take any polygon shape, non-polygon shapes, circular shapes, cone shapes, pyramid shapes or any other protruded 2-dimensional shape or 3-dimensional shape. The asymmetry can be introduced in any wall or in other cases without a wall and along any arbitrary plane.
The connection point between two connectors, or a connector and any other side of an adjacent building block can be in the center of the wall plane, as can be seen for example in FIG. 3 or offset from it as can be seen in FIG. 2 . In typical embodiments, there is at least one connection point, that can be a single one, two points, multiple points, a line, a surface, multiple surfaces or any combination thereof.
Some embodiments show jagged connections as are schematically presented in FIG. 10 and FIG. 11 wherein a plurality of connectors with multiple surfaces are shown to allow for a galvanic connection with low resistance and high durability. Such jagged connectors can include a protrusion (1002), a dent or a hole (1003) and multiple surfaces for the connections themselves (1001).
In other embodiments, the asymmetry is introduced in different parts of building blocks with non-conformal shapes that extend beyond a box, as is depicted in FIG. 5 . Shapes can include ‘L’ Shapes with right angles, different polygon shapes, circular or arc based shapes.
In some embodiments, the walls or other parts of the building blocks are thinner than the rest in order to attribute flexibility to the walls to act as elastic components, in conjunction with spring arms, with other moving components, or in a stand-alone fashion. Such thinning is exemplified in FIG. 6 as component 601, with or without sink, depressions, dents or protrusions (602, 603) to act as part of the thinning, or separately. Wall thinning can be used for added flexibility for purposes of increased durability, improved usability or improved electrical connectivity.
In some embodiments, the asymmetrical connection is designed to exert forces in the perpendicular direction to the building blocks walls. In FIG. 8 a schematic view of an asymmetrically fitting depression and protrusions are shown to exert elastic forces in said direction. The implication of the assembled blocks' forces is shown in FIG. 9A and FIG. 9B, highlighting the advantages of eliminating some of the perpendicular forces and thus increasing the robustness of the system.
In some embodiments, the building blocks include an increase surface area intended for conductivity, for the exertion of friction forces or for any combination thereof. Such embodiments include jagged teeth that fit one into the other as shown in FIG. 10 wherein components (1002) and (1003) are asymmetrically fitting protrusions and dents, with (1001) showing a set of jagged teeth to increase the available surface area for contact.
In some embodiments, an elastic part that can be symmetric or asymmetric is introduced with or without the combination of above mentioned embodiments to increase the ability for motion. FIG. 11 shows for example a symmetric slit introduced for the thinning of at least one part of the building block wall. Similarly, yet in a different embodiment, FIG. 12 shows a dual slit configuration which allows bending of a building block wall with a hemispherical bulge for electrical contact.
Some embodiments have a rotational symmetry around a natural central axis, typically a perpendicular axis to the assembly plane, and an axis that goes through the center of volume or the center of mass of the building block. However, some embodiments of building blocks do not have this rotational symmetry. FIG. 13 shows a single sided building block with an asymmetric connector and a slit for increased flexibility.
In some embodiments, the building blocks are coated in order to form a thin layer of a conductive material around an existing or a manufactured building block. Said coating can be performed chemically, electrochemically, by depositing in an electrolyte reservoir, by dip coating, by brushing, spraying, sputtering or any other coating or depositing method known in the art. The materials introduced for the coating are typically ones with relatively high electrical conductivity such as metals, alloys or composite materials with electrically conductive properties. Such materials include, yet are not limited to, Cr, Cr(III), Sn, Cu, Ni, Al, Mo, Ag, any alloys thereof and any of said metals or others when added to a polymer, polymer mixture, organic compounds, conductive inks or other composite material.
In some embodiments, the coating is modified to have additional surface properties such as anti-corrosion properties. For such purposes, passivation can be induced to create yet thinner layers on the coating itself, additional metals or alloys can be introduced, additional organic compound can be added or other corrosion resistant modifications.
In other embodiments the coating is modified to show surface properties to improve the functional electrical connection by changing the surface roughness. For example, the surface roughness can be reduced to prevent microscopic protrusions and increase the contact area. Such a modification can be performed by etching, electro-etching, mechanical polishing, electro-polishing, sand paper polishing or any other type of method to induce surface smoothness and minimize roughness. Alternatively, the surface roughness can be increased to induce adhesion or control electrical resistance, for example by patterning the surface, corrugating the surface or inducing abrasion over it.
In some embodiments, the connection mechanism is enhanced, or is solely controlled by a spring-like element that exerts forces in the outward direction, or with a component oriented in the outward direction. Such spring like elements can be based on the same material of the building block itself and form by a simple extrusion out of it, they can be made of an additional material such as a plastic, metal, alloy or ceramic addition. In some embodiments, the additional or protruding component is of a leaflet shape, helical (coil) shape, flat spiral shape, arc shape, cantilever shape or any other shape exerting force under pressure.
In some embodiments, the materials used for the spring arms are such that present high elasticity, super elasticity or shape memory properties such as Nickel Titanium alloys, shape memory plastics, Silicon Nitride ceramics, and specifically micro-mechanical Si3N4 that presents high elasticity.
In other embodiments, magnetic materials or components are used for the connecting mechanism. For example, a magnetic material that is introduced to the connection surface can exert forces when present in close proximity to another connector. In some embodiments a permanent magnet is introduced as a thin layer to the aforementioned spring arm or to the connection surface. In some embodiments the material in use is a strong permanent magnet such as Neodymium magnets (NdFeB), Aluminum-Nickel magnets (AlNiCo), Samarium magnets (SmCo), Ferrite magnets, a composite material with magnetic properties or any other material with permanent magnetic properties. In other embodiments, electromagnets or ferromagnetic materials are used separately or in combination with each other to cause the same attraction effect between two sides of a connector. In some embodiments, the electric current through the building blocks is used to energize electromagnetic properties of coils to increase the attraction between two sides of the connecting points.
In some embodiments, magnetic materials are used as described above, in conjunction to mechanical elements allowing for the motion, translation or rotation of one magnet in reference to the other in an adjacent building block in order to allow the alignment of opposing poles one in front of the other to exert a higher force between them. As an illustrative example, the magnet can be a single cylinder with diametrical magnetization orientation and two poles on each side of the building block in an anti-symmetric fashion.
In some embodiments, a permanent magnet is added as a thin layer by some process such as electrodeposition, sputtering, dip coating or other in order to use a small amount of material while allowing for attractive forces between two opposing sides of the connection point between building blocks when in close proximity.
In some embodiments, additional mechanical components are used to increase the pressure or force exerted between adjacent building blocks. Such mechanisms can include, yet are not limited to, buttons, screws, taps, cantilevers, pins, protrusions, holes or others. Such connection assisting mechanisms can trigger a connection at a user action such as pressing or rotation, or can increase the connectivity further by lowering the electrical resistance. Conversely, such mechanisms can be applied in some embodiments to disconnect the building blocks from their adjacent ones.
In some embodiments, an internal mechanism galvanically connects two or more sides of the building block. Such internal mechanism can be a rod, a strip, a wire or any other internally confined component, typically made of a metal, an alloy or a composite material presenting high conductivity. Said internal components can be used as a stand-along mechanism or in conjunction with above-mentioned thin conductive coating in order to decrease the total resistance of the building block.
The invention herein can typically work in conjunction with power supplies such as direct current or alternating current power supplies, batteries of different types, generators, wires and connectors. In some embodiments safety and switching mechanisms are implemented such as, switches, fuses circuit breakers, reed switches, arc fault protection, over-temperature protection, over-current protection, ground fault protection or any other type.
In some embodiments, the invention herein is used in conjunction with external electronics for monitoring, metering or controlling electricity use, function use or other. In some embodiments, one or more component is connected to external control units such as microprocessors, computers, mobile phones or others through some communications protocol such as Internet protocol, Bluetooth, NFC, Wifi, Zigbee or other digital or analog communications.

Claims

1. A system comprising of building blocks intended for use in hobby, amusement, educational or functional construction that present electrically conductive properties to allow integration of electronic, power or electromechanical circuits into the construction, wherein the connection mechanism between adjacent building blocks has at least one asymmetry along an axis or a plane, and does not have a symmetrical reflection property around at least one central plane.

2. The system in claim 1 where the asymmetry is along a plane perpendicular to the natural assembly direction.

3. The system in claim 2 where the asymmetry is anti-symmetric reflection.

4. The system in claim 1 where the building block shows a rotational symmetry around one of its natural central lines such as the line perpendicular to the natural assembly plane.

5. The system in claim 1 where the asymmetry is along a plane parallel to the natural assembly direction.

6. The system in claim 1 where at least one asymmetrical feature is defined around a plane that is not defined

7. The system in claim 1 where the building blocks are coated with a metal, an alloy, a conductive polymer or another electrically conductive material.

8. The system in claim 1 where the building blocks are made at least in part of an electrically conductive material.

9. The system in claim 1 where a magnetic component is introduced to exert forces for increased electrical connectivity.

10. The system in claim 9 where the magnetic component is coated, sputtered or deposited in a thin layer.

11. The system in claim 1 where the building blocks have at least one elastic component to serve as a spring.

12. The system in claim 11 where the elastic component is a spring arm in the shape of a leaflet spring.

13. The system in claim 11 where the spring element is made of a super-elastic material.

14. The system in claim 1 where the connectors use jagged teeth.

15. The system in claim 1 where the connectors are designed to be thinner for increased flexibility.