Molded pulp tiles and structures

Abstract

A simplified form of toy construction set, in which individual tile sections of molded pulp material are joined flexibly and reversibly. Molded tile elements are fabricated with a plurality of grooves, pockets and holes that act as receiving surfaces for assembly with elements that simulate roads and other features and permit the integration of other three-dimensional structural elements. The tile design permits representation of many different three-dimensional environments at different effective scales, with the ability to readily switch between these environments as desired during play.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/088,988, filed Dec. 8, 2014.

BACKGROUND OF THE INVENTION

1. Field of the Invention.

The present invention relates to a toy system fabricated using molded pulp tiles and structures.

2. Background

The present invention relates to a toy system for young children. Various play sets that include tracks along which unpowered toy vehicles can be moved are known. Such play sets have long been a source of entertainment for children. Many of these sets focus only providing roadways or raceways for cars, or require construction skills that render them unsuitable for smaller children.

There is a need for construction toys that extend play beyond conventional tracks and roadways.. Further, there is a need for a unique and different construction set that can easily represent a variety of imaginative play scenarios and that encourages the creativity of the child by showing simple modes by which it may be extended and modified. At the same time, it should be suitable for very small children. In particular, it would be desirable to simulate many different three-dimensional environments at different apparent scales such as a city or town, village, farm, park, fort or zoo and to be able to readily switch between these environments as desired. Such toys should permit many different configurations in three dimensions, thereby enhancing a child's enjoyment and play experience. For example, US 20140017975 A1 teaches the construction of a known environment using a computer system to incorporate images in printed parts. Conventional, injection-molded plastic parts such as Lego™ or similar construction kits may be also used for such purposes. However, since each play element must be constructed individually, modeling and constructing different environments is a complex, time consuming and expensive task. At the same time, plastic materials also have a significant environmental burden and use of alternate, environmentally friendly or ‘green’ materials is desirable.

Molded pulp products (MPP) can be manufactured by a number of processes. These processes permit design, rapid prototyping, and inexpensive manufacture of complex, rigid three-dimensional (3D) structures that have found primary applications in carton design and packaging (US 2515113 A, US20140027337 A1, US 20110278187). They can be readily manufactured in a variety of 3D form factors, in almost any desired color, and with rounded, smooth surfaces that do not yield sharp edges upon fracture. A further desirable aspect is that MPP are less dense than similar products made from wood and plastic and are therefore significantly safer for use by small children. MPP also conform to packaging crushability and other structural tests. MPP are also considered environmentally sustainable (ISO 14000 compliant) since they can be readily manufactured from recycled materials and further recycled after use.

These properties together suggest that molded pulp products can address many limitations in safety, costs and environmental impact of existing plastic (including High density polyethylene) molded parts in many applications for toy design.

SUMMARY OF THE INVENTION

The present invention describes an improved, simplified and inexpensive form of construction set, in which individual tile sections of molded pulp material can be joined quickly and easily by small children. The arrangement enables users to quickly assemble a variety of tile configurations, incorporating tab-and-pocket jigsaw pieces that simulate roads, sidewalks, lanes, footpaths or waterways, and simulating three-dimensional environments on many scales, such as a region/city/town/park or farm) either from provided assembly directions or on a design-it-yourself basis, to provide optimum flexibility in design and assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric projection of a first exemplary embodiment of a single tile element

FIG. 2 is a plan view of a first exemplary embodiment of a single tile element

FIG. 3 is a plan view of one embodiment of the toy system showing four tile elements assembled together using interlocking planar tab-and pocket connectors with a road and sidewalk design

FIG. 4 is a plan view of one embodiment of the toy system showing four tile elements assembled together using interlocking planar tab-and pocket connectors with a road and sidewalk design

FIG. 5 is an isometric view of one embodiment of the toy system showing assembly of a 3D building structure and assembly into the tile element

FIG. 6 is a section view of the building structure assembled into the tile element receiving pocket

FIG. 7 is an isometric view of one possible layout of the toy system with four tile elements assembled together using interlocking planar tab-and pocket connectors and showing integration of building elements

FIG. 8 is a plan view of one embodiment of the toy system showing two tile elements assembled together using a frame with interlocking planar tab-and pocket connectors

FIG. 9 is a plan view of one embodiment of the toy system showing two tile elements assembled together using a frame with interlocking planar tab-and pocket connectors

FIG. 10 is a plan view of one embodiment of the toy system showing two tile elements assembled together using interlocking planar mortise and tenon connectors

FIG. 11 is a section view of one embodiment of the toy system showing two tile elements assembled together using interlocking planar mortise and tenon connectors

DETAILED DESCRIPTION OF THE INVENTION

The present invention describes an improved, simplified and inexpensive form of construction set, in which individual tile sections of molded pulp material can be arranged and joined quickly and easily by small children according to their wish. Molded tile elements are fabricated with a plurality of grooves, pockets and holes that act as receiving surfaces for assembly with tab-and-pocket jigsaw pieces that simulate roads, sidewalks or waterways and permit the integration of other three dimensional structural elements by the child. Using these materials, the tile design permits representation of many different three-dimensional environments at different effective scales such as a city or town, village, construction site, farm, park or zoo, with the ability to readily switch between these environments as desired. The arrangement enables users to quickly assemble a variety of tile configurations, simulating a three-dimensional environment either from provided assembly directions or on a design-it-yourself basis, to provide optimum flexibility in design and assembly. The materials used and the simplicity of the design are highly suitable for very small children. The three dimensional structure of the play surface also directly encourages imaginative play scenarios by suggesting how environments can be built and modified using readily available materials and recycled packaging etc., which further stimulate the creativity of the child.

Referring to FIG. 1-2, in one embodiment, the toy system consists of one or more molded tile elements 1, each with a substantially planar upper surface and with molded features 3 that form a raised ridge that defines functional regions 2, 4, 6, 8 and 10. The upper surface of the tile elements forming the planar base layer comprises a plurality of molded grooves and pockets 5, 7, 9 and 11.

During play, tile elements are arranged together in patterns according to the desire of the user to form a base layer, as shown in the example in FIG. 3. Furthermore the tiles may be rotated so that the relative arrangement of surface features can be altered as required. Any arrangement of tile elements may then, if the user so desires, be joined to form the play surface 12 using tab-and-pocket ‘jigsaw’ elements 13. Each jigsaw section is provided at each end with at least one wide, flat tongue element and one tongue-receiving slot of similar shape and dimensions, configured for convenient push-together joining to secure a pair of adjacent pieces together. In the embodiment shown in FIG. 3, jigsaw elements 13 are laid or push-fitted into receiving grooves molded on the tile surfaces. Alternately, the jigsaw sections can be provided with barbs at one or both side edges to secure adjacent sections to the base tile with a close, accurately aligned fit that assures a flat, smooth surface. In FIG. 3, the tiles are arranged in a 2×2 square matrix, but any regular arrangement of tiles is possible depending on the number of tiles used, since this provides that the functional regions 12 on adjacent tiles are aligned so as to permit them to be ‘bridged’ by jigsaw elements 13.

As shown in FIG. 4, the jigsaw elements 13 are printed and fabricated to simulate a road system 14. In different embodiments these to define features such as ‘roads, sidewalks, lanes, railroads or waterways’ as suggested by the play environment to be modeled. Jigsaw elements may be printed one or both surfaces, providing additional flexibility. In other embodiments, the jigsaw elements may include single or multiple ‘lane’ roads. In other embodiments, roads may also be molded or delineated by stickers, paint or other post-fabrication processes.

FIG. 4 shows one of many possible arrangements of molded tile elements joined by jigsaw pieces to define the play surface 14, and which shows a network of streets and sidewalks defined by the jigsaw elements, all features together suggesting the form of a road system within a model town or city. The envisaged tiles elements can be any practical size from 2-100 cm on a side and any regular or irregular polygonal shape that permits manufacturing, packaging and assembly by the end user. Ideally, larger tiles will permit road and/or train layouts that can accommodate standard sizes of toy vehicles (generally classified as 1:64 scale (though they range from smaller than 1:100 to much larger than 1:64) and measure about 2.5-3 inches, or 6.5-7.5 centimeters, in length. Tiles may be manufactured or modified after manufacturing in a variety of colors to suggest different environments, including urban, freeway, rural or off-road type environments and a variety of climate zone types, such as deserts or mountains.

The tile elements forming the planar base layer include one or more molded features such as grooves, pockets or slots (5,7, 9 and 11 in FIG. 2) that act as receiving surfaces on each tile element. Receiving surfaces permit placement and temporary fixation of other objects (that represent houses or other buildings) on the tiles. In the embodiment depicted in FIGS. 1 and 2, the tile element consists of four areas 4, 6, 8 and 10 defined by the molded ridges 3. Referring to FIGS. 5 and 6, in one embodiment, 3D structures 17, representing buildings, are constructed from planar elements 15, 16 using tabs and pockets. Each planar element is printed on one or more sides to depict the side of building or structure to be represented by the complete assembly 17. In FIG. 5 and FIG. 6, the completed structures such as 17 are inserted into cognate pockets such as 19 on surface 20. The inserted structure is further supported by planar support inserts 21. The planar support insert 21 may be push fitted into the receiving area bounded by molded ridges 22 as shown in FIG. 6. Cylindrical structures 18 and other regular or irregular polygonal receiving pockets 33, 34 and 38 corresponding 3D structures such also envisaged. The mold also permits the fabrication of pockets that will accept multiple shapes such as 34 (in which square and round pockets are combined. As shown in FIGS. 5-7, combinations of 3D structures are used to complete the depiction of the desired play environment 23. In FIG. 7, the environment depicts a cityscape 23 with a plurality of regular polygonal 24, 25 and cylindrical 18 structures that represent buildings. Further planar inserts printed with appropriate designs representing parking lots or parks may be placed in other receiving areas 4, 6, 8 and 10 to complete the depiction of the play environment. It should be obvious that changing the environment to be depicted can be achieved by rearranging building assemblies, planar inserts and jigsaw pieces.

In the embodiment shown in FIG. 3, adjacent tile elements are not joined but are connected at their upper surfaces using tab and pocket ‘jigsaw’ elements 13. In another embodiment, depicted in FIG. 8, they may be physically joined using ‘jigsaw’ tabs and pockets, or molded mortise and tenon joints as in FIG. 9 and FIG. 10.

In the embodiment depicted in FIG. 8, tiles are temporarily joined using an independent frame fabricated in card or paper board with ‘jigsaw’ tabs and pockets. In FIG. 8, Frame 26 is placed over and forms a secure fit with tile element 28. Similarly, Frame 27 is combined with with tile element 29, permitting temporary joining of two or more tiles 30 to permit construction of the play surface 13.

In the embodiment depicted in FIG. 9, the base of the tile is fabricated with a continuous lip 31 and 32 extending from the base of the side walls. This lip may be fabricated with ‘jigsaw’ tabs and pockets to permit joining of two or more tiles to form a play surface 35.

In the embodiment depicted in FIG. 10 and FIG. 11, the base of the tile is fabricated with a discontinuous lip 36 and 37 at the base of the side walls. This lip may be fabricated with mortises and molded tenons 39 to permit joining of two or more tiles to form a play surface 40.

Jigsaw elements 13 are utilized with tiles connected using either of the connecting methods shown in FIG. 3 to FIG. 11 to create the play surface. As in FIG. 4, any regular arrangement of tiles is possible depending on the number of tiles used, since this provides that the functional regions 12 on adjacent tiles are aligned so as to permit them to be ‘bridged’ by jigsaw elements 13.

It should be obvious that the embodiments depicted in the drawings and described above are intended as non-limiting examples of the intended system. In particular, the use of multiple receiving areas on the same tile permits the creation of larger 3D structures.. A further embodiment would permit the creation of receiving areas such as 4, 6, 8 and 10 by the juxtaposition of two or more tiles. Furthermore, the use of jigsaw elements and planar inserts printed on both sides would yield two alternate play environments by placing the desired surface uppermost on the tile surface.

We also envisage other molded 3D features that would represent the natural environment (such as hills, mountains, rivers, lakes and other water bodies), features where the natural and man-made environments intersect, such as quarries or construction sites, molded features (such as depressions, raised areas, slots or posts) that permit integration with other toy systems, such as Lego™ or Duplo™ base plates or Brio™-type railroad tracks.

Claims

1. A modular construction toy system comprising

a plurality of tile elements, made from molded pulp material, each said element comprising side walls, a top having an upper surface that extends from the side walls, the top surface of each said element comprising a plurality of planar receiving surfaces, and an open bottom;

a plurality of interlocking connecting elements forming a substantially planar surface; and

a plurality of elements that can be assembled to form three dimensional geometrical structures.

2. The tile element of claim 1, in which the base of the side walls terminates in a continuous molded lip, wherein said lip extends between 0.01 mm and 100 mm from the base of the side walls.

3. The tile element of claim 2 with a plurality of tabs and pocket to permit temporary joining of two or more tile elements.

4. The tile element of claim 2 with a plurality of mortises and molded tenons to permit temporary joining of two or more tile elements.

5. The tile element of claim 1, in which the base of the side walls terminates in a discontinuous molded lip, wherein said lip extends between 0.01 mm and 100 mm from the base of each side walls.

6. The tile element of claim 5 in which the lip comprises a plurality of tabs and pocket to permit temporary joining of two or more tile elements.

7. The tile element of claim 5 in which the lip comprises a plurality of mortises and molded tenons to permit temporary joining of two or more tile elements.

8. The tile element of claim 1, in which the base of the side walls are joined temporarily by a separate frame comprising a plurality of tabs and pocket to permit temporary joining of two or more tile elements.