Hobby Blocks Including Latently-Adhesive Surfaces

Abstract

Described herein is a block set including a plurality of blocks having latently adhesive surfaces. Also described is a method of creating a bound structure from the individual blocks, including activating the adhesive of the latently adhesive surface of one or more of the blocks; and contacting an activated adhesive surface of the one or more blocks with another of said blocks, to bond the blocks together.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/185,093 filed Jun. 8, 2009, is hereby claimed, and the disclosure thereof is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to hobby-type blocks and specifically relates to a set of blocks that may be adhesively joined, for example to build structures and mosaics.

BACKGROUND

Toy or hobby block sets are used by children to construct simple structures. Hobby blocks are also used by children and adults to build large-scale complex structures, for example replicas of landmark buildings. Such structures can be time- and labor-intensive to build, so a method of permanently preserving blocks in a specific construction is desirable. Currently, users rely on the interlocking properties of the blocks to keep structures joined, however blocks can still become disengaged and structures thus demolished. Alternatively, exogenous adhesive compounds, such as ordinary glue, are applied to the blocks to more strongly adhere them to each other, but utilizing such adhesives can be tedious, messy, and unsuitable for children.

SUMMARY OF THE INVENTION

One aspect of the disclosure is a block set including a plurality of blocks having latently adhesive surfaces.

Another aspect is a method of creating a bound structure from the individual blocks, including activating the adhesive of the latently adhesive surface of one or more of the blocks; and contacting an activated adhesive surface of the one or more blocks with another of said blocks, to bond the blocks together.

For the articles and methods described herein, preferred features, such as components, compositional ranges thereof, substituents, conditions, and steps, can be selected from the various examples provided herein.

Further aspects and advantages will be apparent to those of ordinary skill in the art from a review of the following detailed description, taken in conjunction with the drawings. While the blocks and methods are susceptible of embodiments in various forms, the description hereafter includes specific embodiments with the understanding that the disclosure is illustrative and is not intended to limit the invention to the specific embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as the present invention, it is believed that the invention will be more fully understood from the following description taken in conjunction with the accompanying drawings. Some of the figures may have been simplified by the omission of selected elements for the purpose of more clearly showing other elements. Such omissions of elements in some figures are not necessarily indicative of the presence or absence of particular elements in any of the exemplary embodiments, except as may be explicitly delineated in the corresponding written description. None of the drawings are necessarily to scale.

FIG. 1 is a perspective view of one embodiment of a toy block.

FIG. 2 is a perspective view of the block shown in FIG. 1 with the bottom and rear plans indicated with dashed lines.

FIG. 3 is a top plan view of the block shown in FIG. 1

FIG. 4 is a bottom plan view of the block shown in FIG. 1

FIG. 5 is a side elevation view of two such blocks in an aligned state.

DETAILED DESCRIPTION

Described herein is a hobby block set including a plurality of blocks having latently adhesive surfaces. Also described is a method of creating a bound structure from the individual blocks, including activating the adhesive of the latently adhesive surface of one or more of the blocks; and contacting an activated adhesive surface of the one or more blocks with another of said blocks, to bond the blocks together.

The blocks and method are contemplated to include embodiments including any combination of one or more of the additional optional elements, features, and steps further described below (including those shown in the figures), unless stated otherwise.

As used herein, the term “comprising” indicates the potential inclusion of other agents, elements, steps, or features, in addition to those specified.

The term “block” is used herein for convenience to refer to articles according to the disclosure having latently adhesive surfaces, but is not intended to limit the articles to ones which are block-shaped according to preferred embodiments. In the broadest concept, the shapes, sizes, colors, and textures of the blocks are not intended to be limiting. For example, in one embodiment the blocks will be rectilinear, e.g. typically block-shaped, although the blocks can have, in addition or in the alternative, curvilinear geometries. The plurality of blocks can be the same size and shape, or the blocks can have different sizes and shapes. For example, in one embodiment the blocks will have different sizes and shapes and will be provided with compatible interlocking geometries. In another embodiment, the blocks will be relatively flat, and will have combinations of curved and flat edge profiles, such as jigsaw puzzle pieces, wherein the set of blocks can be assembled together by aligning the edges of the blocks, like a jigsaw puzzle.

The blocks can be joined together, for example to construct vertical or horizontal structures. For example, in one embodiment, the blocks will have compatible interlocking geometries on the top and bottom surfaces and can be stacked vertically. In another embodiment, the blocks will have complementary projections and recesses on side surfaces and can be joined laterally. In one embodiment, for example, the blocks can be relatively thin and have laterally-interlocking surface geometries, such as a jigsaw puzzle. In another embodiment, blocks will have interlocking and aligning geometries on all surfaces and can be joined both vertically and laterally.

As described above, the surfaces of the blocks include a latently adhesive material that can be activated to form adherent bonds. The latently adhesive surfaces can allow the blocks to be bonded without the need for exogenous adhesive, although exogenous adhesive can also optionally be used. Preferably, prior to activation of the adhesive surface, blocks can be repeatedly joined and disengaged. In one embodiment, the latently adhesive material, and preferably the entire blocks, will be made from non-toxic materials suitable for use by children. Put another way, the ingredients used preferably will be non-toxic in the concentrations used.

In one embodiment, the latently adhesive material comprising the block surface will be thermoplastic and preferably also injection-moldable. In one embodiment, the entire block will be injection molded from a latently-adhesive material, such as one described herein. In other embodiments, the block can be formed by casting, by thermoforming, or any other suitable process, optionally including cutting steps (e.g. milling or other tooling).

A preferred embodiment of the surface composition includes a water-soluble polymer, more preferably one that can be dissolved in cold water. For example, the polymer can include a polyvinyl alcohol, for example in an amount in a range of 60% by weight or greater, based on the total weight of the formulation (wt. %), for example 60 wt. % to 92 wt. % or 80 wt. % to 92 wt. %. The polyvinyl alcohol polymer preferably has a degree of a hydrolysis in a range of 70% to 99%, preferably in a range of 88% to 98%. Preferably, the 4% solution viscosity of the polyvinyl alcohol at 23° C. is in a range of about 5 cps to about 50 cps, more preferably about 8 cps to 30 cps. For example, a cold water-soluble polymer can include a PVOH having a 4% solution viscosity at 23° C. of about 8, and a degree of hydrolysis of about 88. A hot water-soluble polymer can preferably have a blend of one or more low viscosity, high degree of hydrolysis PVOH polymers as principal PVOH components, and one or more high viscosity, low degree of hydrolysis PVOH polymers as secondary PVOH components.

Polymer formulations will preferably further include one or more plasticizers. Suitable plasticizers include, but are not limited to, glycerin; low-molecular weight polyethylene glycol (e.g., having a liquid consistency, for example having and a molecular weight such as MW 200, MW 300, and MW 600); monoacetin; triacetin; triethyl citrate; sorbitol; 1,3-butanediol; D-glucono-1,5-lactone; and, propylene glycol. The plasticizer permeates the polymer structure, disrupts intermolecular hydrogen bonding, and permanently lowers intermolecular attractions. Plasticizers are preferably included in an amount in a range of 5 wt. % to 25 wt. %, or 8 wt. % to 25 wt. %.

The polymer formulation may optionally include secondary additives such as antifoams, extenders, extrusion aids, compounding aids, lubricants/release agents, surfactants, and anti-blocking agents, as is known in the art. Suitable lubricants/release agents include, but are not limited to, fatty acids and their salts, fatty alcohols, fatty esters, fatty amines, fatty amine acetates, fatty amides, and combinations thereof. Preferred lubricants/release agents are fatty acids, fatty acid salts, and fatty amine acetates. Examples include, but are not limited to, calcium stearate, magnesium stearate, stearic acid, and stearamide.

Suitable fillers/extenders/antiblocking agents/detackifying agents include, but are not limited to, starches, modified starches, hydroxyethylated starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, carboxymethylcellulose, silica, metallic oxides, calcium carbonate, talc, mica, clays, and combinations of the foregoing.

A preferred plasticized, cold water soluble, PVOH-based, extrudable polymer is sold under the trade name MONOPOL C100 by MonoSol, LLC (Merrillville, Ind., USA) and has the formulation properties (at 23° C., 50% rh) described below in Table 1.

TABLE 1
CHARACTERISTICS	ENGLISH	METRIC
Melt Flow Index (ISO 1133,	—	27	g/10 min
190 C., 21.6 kg)
Density	—	1.28	g/cm3
Melting Point, DSC	365°	F.	185°	C.
Tensile Strength at Yield	4,400	psi	30	MPa
(ASTM D638)
Elongation at Break	140%	140%
(ASTM D638)
Flexural Modulus	36,000	psi	248	MPa
(ASTM D790)
Izod Impact Strength	13.7	ft-lbf/in	7.3	N-m/cm
(ASTM D256)
Durometer Hardness,	72	72
Shore D (ASTM D2240)
VICAT Softening Point, 10N,	248°	F.	120°	C.
50° C./hr (ASTM D1525)

A preferred plasticized, hot water-soluble, PVOH-based, extrudable polymer is sold under the trade name MONOPOL H700 by MonoSol, LLC (Merrillville, Ind., USA) and has the formulation properties (at 23° C., 50% rh) described below in Table 2.

TABLE 2
CHARACTERISTICS	ENGLISH		METRIC
Melt Flow Index (ISO 1133,	—	10	g/10 min
220 C., 10 kg)
Melting Point, DSC	410°	F.	210°	C.
Tensile Strength at Yield	5,300	psi	36	MPa
(ASTM D638)
Elongation at Break	150%	150%
(ASTM D638)
Flexural Modulus	58,000	psi	400	MPa
(ASTM D790)
Notched Izod Impact Strength	25.5	ft-lbf/in	13.6	N-m/cm
(ASTM D256)
Durometer Hardness, Shore D	74	74
(ASTM D2240)
VICAT Softening Point, 10N,	343°	C.	173°	C.
50° C./hr (ASTM D1525)

Each block can be homogenous in composition, with the core and surface including the same latently adhesive material. The block core can alternatively include a non-adhesive compound or it can be hollow. A preferred embodiment includes a homogenous composition, for example to facilitate manufacturing utilizing injection molding.

The blocks can have smooth surfaces or the surfaces can be provided with features for aligning and/or interlocking blocks to each other. The blocks can also be provided with aligning and/or interlocking geometries. For example, the block surfaces can contain projections, whereby one or more projections on a first block will align with the non-recessed surface portions of a second block, and optionally will engage with (e.g., by frictional engagement) the non-recessed surface portions and/or surface projections on the second block (e.g., via frictional engagement between side wall surfaces of the projections with each other). The block surfaces also can include recesses, for example recesses that are complementary to projections on block surfaces, e.g. for contacting alignment and optionally frictional engagement between blocks.

Various examples of such block features and geometries are known in the art, including LEGO bricks (The LEGO Group, Billund, Denmark), MEGA BLOKS bricks (MEGA brands, Inc., Montreal, Canada), and Best-Lock bricks (Best-Lock Construction Toys, England), all of which employ stud-and-tube coupling system for frictional engagement between blocks. See, for example, Danish page 92683 C (Jan. 29, 1962), the disclosure of which is incorporated herein by reference. Another example of such blocks includes KRINKLES/BRISTLE BLOCKS (Battat Inc., Plattsburgh, N.Y.), which employs evenly-spaced rows and columns of bristle-shaped projections, wherein the gaps formed by the projections are approximately the same size as the projections, thereby providing for frictional engagement when the bristle-shaped projections from a first block are pushed into the gaps of a second block. Another example includes jigsaw puzzles, e.g. wherein the blocks are relatively thin and have features intended for lateral alignment.

The figures herein illustrate one embodiment of blocks and block features designed for alignment and, optionally, interlocking. As shown in FIGS. 1 and 3, a plurality of cylindrical projections 2 on side 4 of block 10 are uniformly spaced and sized. As shown in FIGS. 2 and 4, a plurality of cylindrical recesses 12 on side 14 on a first block 10 are dimensioned to receive the projections 2 of a second block 10, for example in adjacent engagement, creating a unit of two aligned blocks as illustrated in FIG. 5. The projections 2 and recesses 12 can be sized for frictional engagement, such that the blocks remain joined if a first block 10 (e.g., the top block in FIG. 5, as shown) is lifted off a second block (e.g., the bottom block in FIG. 5, as shown). For example, the diameters of projections 2 can be slightly larger than the diameters of recesses 12, to provide for a press fit engagement. Consistent with the disclosure herein, if the blocks, or at least the surfaces of projections 2, and preferably also the surface of side 4, include an activated latently-adhesive material, then the blocks will also be bonded together, and preferably fused together.

Individual blocks may be joined into a bound structure using a method including activating the latent adhesive surface of a block and contacting blocks together. It is also conceived that a first block having one or more latently-adhesive surfaces can be bound to one or more blocks that do not have latently-adhesive surfaces. Structures or mosaics can be assembled from such blocks by ensuring that the adhesive blocks are spaced between non-adhesive blocks.

Blocks can be utilized to compose structures including mosaics and three-dimensional constructions. A preferred embodiment of activation is applying water to dissolve a block surface comprised of a water-soluble compound. Water as a solvent is readily accessible, inexpensive, and non-toxic, so it is appropriate for children to use. Other methods contemplated for activating the latent adhesive are employing solvents other than water, heating the surface, abrading the surface, and applying pressure to the surface. Blocks may be joined through arranging, aligning, or interlocking blocks to create contacting surfaces.

The adhesive can be activated prior to contacting blocks or subsequent to assembling multi-block units. A preferred embodiment is to activate an adhesive surface prior to contacting blocks, to maximize the surface area of activated adhesive. For example, surface 4 of block 10 in FIG. 1 is dampened with water and then interconnected with side 14 of a second block 10, such as shown in FIG. 5. Alternatively, water can be applied to the junction of side 4 of the bottom block and side 14 of the top block after the blocks are joined (e.g. at the side walls 15). In another embodiment, the surface of side 4 of a first block 10 is dampened with water, and the surface of side 14 of a second block 10 is also dampened with water, and then the blocks are joined as described above. The water can be applied by a sponge, by misting, or by any other suitable means.

Contacting activated surfaces of blocks together creates adherent bonds. The bond can be permanent, resulting in unbreakable structures, for example if the surfaces of the blocks are solubilized, and then joined. The bond could be initially semi-permanent, allowing for adjustment of blocks after activating the adhesive, and then permanent. The bond could be non-permanent, permitting the disengagement of blocks. A preferred embodiment is a permanent bond to allow for the creation of lasting structures. In one embodiment, the degree of bonding between blocks can be temperature dependent. In another embodiment, the degree of bonding between blocks can be pressure dependent. A preferred method includes activation and fusion of adhesive surfaces at room temperature and atmospheric pressure.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a degree of hydrolysis disclosed as “88%” is also intended to mean “about 88%.”

All documents cited herein are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Throughout the specification, where compositions are described as including components or materials, it is contemplated that the compositions can also consist essentially of, or consist of, any combination of the recited components or materials, unless described otherwise. The invention illustratively disclosed herein suitably may be practiced in the absence of any element or step which is not specifically disclosed herein.

The practice of a method disclosed herein, and individual steps thereof, can be performed manually and/or with the aid of or automation provided by electronic equipment. Although processes have been described with reference to particular embodiments, a person of ordinary skill in the art will readily appreciate that other ways of performing the acts associated with the methods may be used. For example, the order of various of the steps may be changed without departing from the scope or spirit of the method, unless described otherwise. In addition, some of the individual steps can be combined, omitted, or further subdivided into additional steps.

Example

Two pairs of structures made of a water-soluble injection-moldable polymer were tested for their fusing characteristics. The polymers were made from polyvinyl alcohol. One pair of structures was made with a hot water-soluble polymer, and one pair was made with a cold water-soluble polymer.

A damp sponge was used to wet the surface of one part from each pair to solubilize the surface polymer and activate the latent adhesive. The part with the activated surface was aligned with its partner part made of the same polymer so that the activated surface of one part contacted the second part. The structure formed from parts made with a cold water-soluble polymer fused in about 2 minutes at room temperature. The structure formed from parts made with a hot water-soluble polymer fused in about 12 hours at room temperature. No heat was applied during fusion.

Claims

1. A block set that may be used to form unbreakable structures and mosaics, comprising a plurality of blocks comprising latently adhesive surfaces that can be activated to form permanent bonds without exogenous adhesive.

2. The block set in accordance with claim 1, wherein the surfaces of said blocks are smooth.

3. The block set in accordance with claim 1, wherein each of said blocks comprises one of or both projections and recesses on at least one surface of said blocks, the projections and/or recesses disposed for contacting alignment of said blocks with respect to each other.

4. The block set in accordance with claim 3, wherein said blocks comprise both surface projections and surface recesses, and said surface projections and said surface recesses are sized for frictional engagement between each other, respectively.

5. The block set in accordance with claim 3, wherein said projections complement in shape said recesses on adjacent blocks.

6. The block set in accordance with claim 1, wherein said blocks can be repeatedly joined and disengaged prior to activation of the latent adhesive.

7. A block set in accordance with claim 1, wherein the surfaces of the blocks comprise a water-soluble, injection-moldable polymer.

8. The block set in accordance with claim 7, wherein the water-soluble polymer comprises a polyvinyl alcohol.

9. The block set in accordance with claim 8, wherein said compound further comprises a plasticizer.

10. The block set in accordance with claim 7, wherein said polymer is soluble in cold water.

11. The block set in accordance with claim 1, wherein the blocks have a homogenous, injection-molded structure.

12. The block set in accordance with claim 1, wherein the core of each block is hollow.

13. A method of creating a bound structure from individual blocks, comprising:

providing a plurality of blocks comprising latently adhesive surfaces;

activating the adhesive of a latently adhesive surface of one or more of the blocks; and

contacting an activated adhesive surface of the one or more blocks with another of said blocks, to permanently bond said blocks together.

14. The method in accordance with claim 13, wherein said activating comprises wetting the latently adhesive surface with water.

15. The method in accordance with claim 14, comprising performing said contacting while the wetted surface is damp.

16. The method in accordance with claim 13, wherein said activating comprises solubilizing the latently adhesive surface.

17. The method in accordance with claim 13, comprising activating a latently adhesive surface on each of two of the blocks, and contacting said activated surfaces with each other, to permanently bond said blocks together.

18. The method in accordance with claim 13, comprising activating said latently adhesive surface at room temperature.

19. The block set in accordance with claim 3, wherein the blocks have a homogenous, injection-molded structure.

20. The block set in accordance with claim 8, wherein said polyvinyl alcohol polymer is soluble in cold water.