CA2193667C

CA2193667C - Flexible foam construction toy and method of manufacturing same

Info

Publication number: CA2193667C
Application number: CA002193667A
Authority: CA
Inventors: Arthur M. Ganson
Original assignee: Hands On Toys Inc
Current assignee: Hands On Toys Inc
Priority date: 1994-06-27
Filing date: 1995-06-26
Publication date: 2005-03-29
Anticipated expiration: 2015-06-26
Also published as: US5498190A; US5769994A; DE69531681D1; EP0767696B1; EP0767696A1; NZ289306A; JP3675479B2; AU2910495A; JPH10505512A; WO1996000117A1; EP0767696A4; AU697797B2; CA2193667A1

Abstract

A flexible foam construction toy (10), comprising: an elongated foam body (1 2) having a central aperture (20) with a first diameter, a flexible wire (14), with a second diameter approximately equal to the firs t diameter, t 20 90, and located along the central aperture (20) of the foam body (12) such that its ends (16, 18) are within a distance no greater than the diameter of the foam body (12) (or the diameter of the largest circle that can be drawn completely within a non-cylindrical foam body) from either end of the foam body (12); and adhesive between the wire (14) and the foam body (12) for assisting to maintain the wire (14) within the foam body (12).

Description

~Q 9610011'1 ~~ ~ ~ °~ 2 ~ 9 3 6 6 7 PCTIUS95/08055 FLEXIBLE FOAM CONSTRUCTION TOY
AND METHOD OF MANUFACTURING SAME

4 This invention relates to a flexible foam construction toy that can be bent in a variety of shapes.

8 One type of child's construction toy is a type which consists of a number of 9 interconnectable pieces. Often these pieces are rigid. Sometimes the pieces have the interconnection structures built therein, and other times there are separate pieces that act 11 to interconnect other pieces. Although these rigid toy pieces have great variety, the child 12 is limited by the particular size and shape of the pieces of the construction toy set.
13 Some such interconnectable construction toy sets use flexible pieces. One such 14 toy uses plastic-coated wire pieces with special end designs which allow the pieces to be interconnected. Even this limits the child's use of the toy, however, as the pieces are not 16 adapted to be interconnected at places other than their ends. Additionally, the relatively 17 thick wire and relatively dense plastic coating are sufficiently massive that they 18 effectively limit the size of the toy pieces.

It is therefore an object of this invention to provide a construction toy which can 21 be used to make virtually any shape of any size.
22 It is a further object of this invention to provide such a construction toy in which 23 the toy pieces can be interconnected anywhere along their lengths.
24 It is a further object of this invention to provide such a construction toy in which the toy pieces can be directly interconnected, or interconnected with separate 26 interconnection pieces.
27 It is a further object of this invention to provide such a construction toy in which 28 the pieces are extremely light so that they can be made very large and/or long.
29 This invention results from the realization that a superior construction toy may be accomplished by making different toy shapes out of extruded foam with a relatively thin, w0 96100117 S ~ ~ ~- ~~ ~ ,'' 2 ~ 9 ~ 6 6 7 pCTIUS95108055 i flexible wire inserted in a central aperture in the foam piece and held therein with 2 adhesive and with enlarged ends which inhibit piercing of the foam by the wire ends.

3 This invention features a flexible foam construction toy, comprising: an elongated 4 foam body having a central aperture with a first diameter; a flexible wire, with a second diameter approximately equal to the first diameter, t20% > and located along the central ' 6 aperture of the foam body such that the wire ends are each within a distance no greater 7 than the diameter of the foam body (or the diameter of the largest circle that can be 8 drawn completely within a non-cylindrical foam body) from either end of the foam body;
9 and adhesive means between the wire and the foam body for assisting to maintain the wire within the foam body. The wire may include enlarged ends, with a third diameter 11 greater than the second diameter. The enlarged ends may be integral with the wire, or 12 may be separate structures bound to the ends of the wire. The wire is preferably 13 aluminum, and may be 0-temper aluminum.
14 The adhesive means may include heat, glue, epoxy, heat activated adhesive or other adhesives. The foam body may be made from polyurethane or polyethylene with 16 or without additives. The ends of the foam body may be sealed or capped to assist in 17 keeping the wire in the aperture. The wire may have a diameter between 1/32" and sh".
18 The size of the wire adheres to the following principal: The ratio of the foam OD to the 19 diameter of the wire will range from 4:1 to 20:1 for a 2.5 lb per cubic foot (pcf) foam.
The upper range of this ratio will change as the foam density changes by a factor of:
21 2.S/density of foam used. For example a 1.25 Ib pcf foam would have the ratio of 4:1 22 to 2.511.25 x 20:1 or 40:1. A 5 lb pcf foam would have the ratio of 2:1 to 10:1. In the 23 case of non-cylindrical bodies, the measurement used for this ratio should be the diameter 24 of the largest circle that can be drawn completely within the figure.
In a more specific embodiment, this invention features a flexible foam 26 construction toy, comprising: an elongated foam body having a central aperture with a 27 first diameter, and sealed ends; a flexible wire, with a second diameter of at least 1132", 28 and approximately equal to the first diameter, t20%, and located along the central 29 aperture of the foam body; enlarged wire ends fixed to or integral with both ends of the wire, and ending within a distance no greater than the diameter of the foam body (or the 31 diameter of the largest circle that can be drawn completely within a non-cylindrical foam 32 body) from either end of the foam body; and adhesive between the wire and the foam ~G 96100117 1 ~ f-' ~ ~ ~ ''~ ~ ~ ~ 3 6 6 7 PCT/US95/08055 1 body for assisting to maintain tine wire within the foam body.
2 Also featured is a method of manufacturing a flexible foam construction toy, ~ 3 comprising the steps of: extruding an elongated foam shape, having a central aperture 4 with a first diameter; providing a piece of flexible wire; substantially coating the wire or the internal aperture of the foam with an adhesive; inserting the wire into the central 6 aperture of the foam shape so that the wire is within the Foam shape; and closing off the 7 ends of the foam shape to assist in maintaining the wire within the foam shape. The 8 llength of the wire may be equal to that of the foam shape or shorter or longer than the 9 ffoam shape by a distance no greater than the diameter of the foam body (or the diameter of the largest circle that can be drawn completely within a non-cylindrical foam body).
11 The method may further include the step of enlarging the wire ends before insertion into 12 the foam shape, which may be accomplished by balling the wire at its ends, or by fvcing 13 enlarged structures to the ends of the wire. If a heat activated adhesive is used, i2 can 14 he reactivated by heating with hot air, or by heating the metal wire with rf induction.
-g~F D~CRIPTION OF THE DRAWINGS
16 Other objects features and advantages will occur to those skilled in the art from 17 the following description of preferred embodiment, and the accompanying drawings, in 18 which:
19 Fig. 1 is a side view of one form of a flexible foam construction toy according I:o this invention with a portion of the toy removed to detail the interior structure;
21 Fig. 2 is an end view of the toy of Fig. 1;
22 Fig. 3 is a partial cross sectional view of the toy of Fig. 1;
23 Fig. 4 is a view similar to that of Fig. 1 for another style of flexible foam 24 construction toy according to this invention;
Fig. 5 is an end view of the toy of Fig. 4;
26 Fig. 6 is a partial cross sectional view of the toy of Fig. 4;
27 Fig. 7 is a cross-sectional view of another embodiment, detailing a manner of 28 closing off the end of the foam body with a cap;
29 Figs. 8A through 8D are an unbent and three bent shapes, respectively, of a flexible foam constrnction toy according to this invention having a circular cross section;
31 Figs. 9A through 9D are similar views for a toy having a square cross section;

'~ t~. ; ~ ~ ~::~ r ~ 19 3 6 6 7 PCT/US95108055 1 Figs. l0A through lOD are similar views for a toy-having a triangular cross 2 section;
3 Figs. 11A through 11Dare similar views for a toy having a rectangular cross , 4 section;
Figs. 12A through 12D are similar views for a toy having a rectangular cross ' 6 section and holes therethrough; and 7 Fig. 13 is a view of many pieces put together to form a fanciful construction.
8 DF~~TION OF THE PREFERRED EMBODIMENTS __ .
9 There is shown in Figs. 1 through 3 flexible foam construction toy 10 according to this invention. Toy 10 is made from an elongated foam body 12 having central 11 aperture 20 which is typically approximately 1/32" to ll2" in diameter. The foam body 12 can take a variety of shapes as illustrated in Figs. 7 through 11, for example. Flexible 13 wire 14 having enlarged ends 16 and 18 is embedded within body 12 along aperture 20.
14 Wire 14 is preferably zero-temper aluminum wire having a thickness between 1/32" and 1/2". The size of the wire adheres to the following principal: The ratio of the foam OD
16 to the diameter of the wire will range from 4:1 to 20:1 for a 2.5 lb per cubic foot (pcf) 17 foam. The upper range of this ratio will change as the foam density changes by a factor 18 of: 2.Sldensity of foam used. For example a 1.25 lb pcf foam would have the ratio of 19 4:1 to 2.5/1.25 x 20:1 or 40:1. A 5 lb pcf foam would have the ratio of 2:1 to 10:1.
In the case of non-cylindrical bodies, the measurement used for this ratio should be the 21 diameter of the largest circle that can be drawn completely within the figure. Enlarged 22 ends 16 and 18 in this case are formed by enlarging the wire ends, for example by 23 balling the ends in a coining or molding process.
24 . Toy 10 is manufactured first by extruding foam body 12 and cutting off the extrusion to the desired length. The foam is preferably polyurethane or polyethylene with 26 or without additives. This material has enough flexibility to allow wire 14, including 27 enlarged ends 16 and 18, to be inserted into aperture 20. Before wire 14 is inserted in 28 the aperture, it or the aperture is coated with an adhesive such as a glue, epoxy, heat 29 activated adhesive or other adhesives to assist in maintaining the wire in place within body 12. If a heat-activated adhesive is used, it can be activated by placing the toy in 31 an oven, or by heating the metal wire by rf induction.

~O 96100117 '~, :_ j ~ a°. si ~ ~ 19 3 6 6 7 PCTlUS95/08055 S
1 It has been found that the ends of wire 14 should be within a distance equal to the 2 diameter of a cylindrical foam body, or the diameter of the largest circle that can be 3 drawn completely within a non-cylindrical foam body, from the ends of body 12. To 4 further assist in maintaining wire 14 in place and preventing it from puncturing body 12 or slipping out one of the ends of aperture 20, body 12 is preferably closed off after the 6 wire is inserted. If the ends are sealed, the result is that the body ends such as end 22 7 are slightly smaller than the diameter ~of the remainder of body 12. This sealing serves 8 to help close off the open ends of aperture 20 and may be achieved with heat, glove, 9 epoxy, heat activated adhesive, or other adhesives.
An alternative construction of toy l0a is shown in Figs. 4 through 6. Wire 14a 11 is provided with enlarged ends in this case by sealing or gluing caps 32 and 34 on the i2 ends of the wire. These caps may be similar to wire nuts. Another type of enlarged end 13 is made by looping the ends back on themselves. The construction may also be 14 accomplished with two half foam pieces (such as half circular cross-section) with a central channel, into one of which wire 14a is laid before the halves are adhered together, 16 leaving seam 20a.
17 Fig. 7 details another manner of closing off the ends of the foam body to prevent 18 the wire from poking out through the ends. This method can also be used to cap wire 19 ends when the wire is longer than the foam body. Wire 14b has enlarged end 35 which can be formed by stamping. After wire 14b is insertrd in channel 20b in the center of 21 foam body 12b, plastic end cap 37 is fitted over the end of wire 14b. Cap 37 has 22 shoulder 38 that snaps over and mates with corresponding shoulder 36 of wire 14b to 23 keep cap 37 on the end of wire 14b.
24 The foam construction toy of this invention can take any one or more of virtually unlimited shapes. In manufacturing, it is advantageous to choose shapes which may be 26 extruded. One shape is a circular tube 50 through SOc, Figs. SA through 8D.
Figs. 8B
27 and 8D illustrate three of a virtually unlimited number of shapes which that toy may be 28 bent into. Similar drawings are shown for tubes 60 through 60c with a square cross 29 section, Figs. 9A through 9D; tubes 70 through 70c with a triangular cross section, Figs.
l0A through IOD; rectangular bars 80 through 80c with a rectangular cross section, Figs.
31 11A though ilD; and rectangular bars 90 through 90c, Figs. 12A through 12D, which 32 have a rectangular cross section and include a number of through-holes such as hole 91 wo vs~oom ~ ~ ~ ~ ~, P i ~ ~ 9 3 6 6 7 P~T~s9~ososs 1 which allow this piece to be connected to the tube-shaped pieces by passing the tubes 2 through the holes.
3 Fig. 13 is a drawing of a fanciful assembly made with a number of flexible foam , 4 construction toy pieces according to this invention. Rectangular base pieces 100 and 101 have a cylindrical hole for supporting cylindrical pieces SOd and SOe which in turn 6 support the other pieces, including rectangular bars 90a and 90b which have through 7 holes as shown, disk-shaped pieces 102 and 104 which may have holes for holding 8 cylindrical pieces such as SOq, longer cylindrical pieces SOf through SOh, shorter 9 cylindrical pieces SOi through SOp, star-shaped piece 106, triangular piece 108, and sawtooth piece 110 which may have one or more holes adapted to receive another piece 11 of the set to allow the user to create myriad fanciful designs.
12 Although specific features of this invention are shown in some drawings and not 13 others, this is for convenience only as each feature may be combined with any or all of 14 the other features in accordance with the invention.
Other embodiments will occur to those skilled in the art and are within the 16 following claims:
17 what is claimed is:

Claims

1. A flexible foam construction toy set, comprising:
a plurality of flexible, wire core, elongated foam tube, toy pieces having ends, each wire core foam tube toy piece made from a foam tube with an embedded flexible wire core, and capable of retaining a bent shape due to the wire core; with a plurality of the wire core foam tube toy pieces interconnected to one another by wrapping one foam tube toy piece crosswise fully around one or more other foam tube toy pieces, to interconnect the wire core foam tube toy pieces without separate interconnection structures;
wherein the foam tube toy pieces are bent in locations apart from such interconnections, to create a fanciful design;
a number of foam adjunct pieces, each having one or more through holes sized and shaped to fit a wire core foam tube toy piece therethrough, and to grip the tube of the wire core foam tube toy piece, to add the adjunct pieces to the wire core foam tube toy pieces, wherein one or more of the adjunct pieces have a single such through hole and are coupled to a single foam tube toy piece, and one or more other adjunct pieces have at least two through holes that couple them to at least two foam tube toy pieces, to maintain such at least two foam tube toy pieces in a spaced-apart relationship; and a base member having a plurality of openings sized and shaped to fit therein one or more of the wire core foam tube toy pieces, with wire core foam tube toy pieces inserted into the base member openings to hold the set upright on the base member.

2. The flexible foam construction toy set of claim 1 in which at least one of the wire core foam tube toy pieces has a regular geometric cross-sectional shape including circular, triangular and rectangular.

3. The flexible foam construction toy set according to claim 1, in which at least some of said wire core foam tube toy pieces include a wire core that is shorter than the foam tube.

4. The flexible foam construction toy set of claim 3 in which said wire core foam tube toy pieces with a wire core shorter than the foam tube include a foam tube with an aperture in which the wire core is located.

5. The flexible foam construction toy set of claim 4 in which said wire core foam tube toy pieces with an aperture include foam tubes with their ends closed around the aperture, to fully encapsulate the wire core.

6. The flexible foam construction toy set of claim 5 in which the wire cores have enlarged ends.

7. The flexible foam construction toy set according to claim 1, further including an adhesive substance between said wire core and said foam tube of said wire core foam tube toy pieces, to more firmly hold said wire core in said foam tube.

8. The flexible foam construction toy set according to claim 1, in which at least some of said wire core foam tube toy pieces have a generally circular cross-sectional shape.

9. The flexible foam construction toy set according to claim 1, wherein at least some of the wire core foam tube toy pieces have a foam tube diameter to wire diameter ratio of from about 4 to about 20.