Construction Playset with Foam Noodles Miter and Fastener

[0001] The present application is a Continuation in Part of U.S. application Ser. No. 15/951,199 that is a Continuation in Part of U.S. application Ser. No. 15/344,333 claims benefit under 35 U.S.C. 119(e) of U.S. Provisional Applications 62/251,039 filed on Nov. 4, 2015, the disclosure of which are incorporated herein by reference.

[0002] The disclosed technology relates generally to constructing playsets and more specifically to soft, creative environments that can be built to tower above a child's head without concern of injury due to collapse. These polyethylene foam noodles are hollow custom extrusion profiles that resemble logs and hereinafter referred to as “foam logs” or “logs”. These logs are connectable to each other with the use of molded fasteners designed to compress to pass easily through holes formed through the wall of each of the foam logs. These logs are easily cut with a toy saw and a miter with adjustable angles to help children cut and remove wedges of the logs so the logs can be bent into predictable curves to allow construction of ships and other designs that include curved shapes.

[0003] Children's blocks have forever been a source of creative play. Frank Lloyd Wright famously credits his childhood blocks as a significant outlet for his creative mind from a very early age. While playing with blocks is often an immersive experience, few sets of blocks allow for the construction of structures that are full size play sets for children.

[0004] In one objective of the current disclosed technology a construction playset having a hollow plastic extrusion log and said hollow plastic extrusion log comprising; a front side and a back side; a first end and a second end; a top side and a bottom side. Each top and bottom side having a substantially flat planar surface and a plurality of portals in the substantially flat planar surface and the portals extending from an outer surface of the log to an inner hollow surface of the log. The plurality of portals extending the length of the top and bottom sides substantially flat planar surface and wherein the log is stackable by aligning the bottom side of said log with an adjacent top side of another log to thereby construct the desired lightweight self-supporting structure. Also, a pair of channels on the front and back side of the inner hollow surface, wherein the channels are operable to allow the log to be flattened predictably.

[0005] In another objective, the construction playset where the channel pair are a thinning of the front and back walls of the log in any geometric shaped extrusion.

[0006] In yet another objective of the playset at least two adjacent logs are removably attached to a fastener, and the fastener is multidirectional thus enabling the adjacent log to be rotated toward a specific direction and configured to interchangeably attach to each log. The log is stackable with adjacent logs and fasteners are placed between and inside apertures of adjacent logs to thereby construct the desired lightweight self-supporting structure; and wherein fasteners are operable to compress at tips on two ends to allow to the fastener to easily pass through a portal in the log and then expand back to an original geometry of the fastener and attach two adjacent logs together.

[0007] In a further objective the fasteners of the construction playset have an eyelet operable to allow items such as string to be passed through and the fasteners are made of injection molded plastic. These fasteners extend from outside of the log into the hollow area of the log through the portals in the log with an interference fit so the fastener can remain removably attached to the log until the fastener is deliberately removed.

[0008] Another objective of the disclosed technology is to provide an angled miter to assist the cutting angled cuts in the logs of the construction playset. The angled miter may have guides operable to move to different angles to facilitate cutting of different angles in the log.

[0009] One objective of the disclosed technology is providing a method of using a construction playset comprising the following steps: selecting a plurality of logs, each log comprising; a front side and a back side; a first end and a second end; a top side and a bottom side; each top and bottom side having a substantially flat planar surface; a plurality of apertures in the substantially flat planar surface and the apertures extending from an outer surface of the log to an inner hollow surface of the log; said plurality of apertures extending the length of the top and bottom sides substantially flat planar surface; The method continues with determining the length of the logs needed for building a toy structure; determining what logs need to be cut; counting the number of apertures on the logs needing to be cut to determine where to cut the logs and sawing the logs to appropriate sizes; determining if any round or curved logs are needed and determine the amount and size of angled cuts to make into a log such that a wedge of the log can be removed allowing the log to be bent into a curve.

[0010] Continue of the method by placing one of the plurality of logs on the ground or on a support horizontally with one of the substantially flat planar surfaces facing the ground or support; placing a connector or plurality of connectors into the apertures of the log placed on the ground or support; determining which of the plurality of logs is a second log to be placed on top of the log already placed; placing the second log, wherein the second log is stackable on the log already place and connectors are between and inside apertures of adjacent apertures of the logs. Finally, placing the curved log where needed and fastening to another log; wherein this method continues with a plurality of adjacent logs and fasteners are placed between and inside apertures of adjacent logs to thereby construct the desired lightweight self-supporting structure.

[0011] In a final objective of the disclosed technology there is a method of using the construction playset to create a curved or round log comprising the following steps: selecting a log and determining the length and/or an angled cut of the log needed; placing an angled miter on a flat surface; positioning guides on the angled miter to desirable positions. Then placing the log in the angled miter and positioning miter guides to the correct placement to cut a desired angle or wedge in the log and placing a saw on the guides then sawing the angle or the wedge out of the log.

[0021] The disclosed technology relates to a building system for children that allows them to construct structures from hollow foam extrusions or foam logs that are stackable so they can make playsets of their own design or existing designs in which they can hide, play, and let their imaginations soar.

[0022] A log for purposes of this disclosure is defined as an elongated, hollow cylinder with two or more flattened exterior sides. The flattened sides allow the logs to be easily stacked like logs in a log cabin. The logs are made of the same material as foam “pool noodles”. In an embodiment the logs are of a larger diameter than most pool noodles with three relatively flat sides each with holes or portals and a fourth side that is curved with no holes so playsets appear to be made from large foam logs.

[0023] FIG. 1 by way of example illustrates two foam logs (10) having a custom extrusion profile with a thinned section, or channel (14) in two opposing walls so they can be flattened to reduce shipping box size and costs. The channel (14) may function as opposing hinges so the log can be flattened with less force. The channel (14) may be the full length of the log reducing the required compression force and making the log (10) fold predictably. The channel (14) aids the flattening of the log (10) when its profile geometry is symmetrical, asymmetrical, curved, or flat. This channel (14) detail in the log (10) profile is critical to making the product line affordable by reducing shipping costs dramatically. Compressed logs (20) illustrate the ease of compression before shipping. When compressed logs (20) are unpacked, they return to their original extrusion non-compressed, full width.

[0024] FIGS. 2 and 3 illustrate logs (10) being connected to each other with a double ended fastener (1). FIGS. 4a-c illustrate that fasteners (1) have tips (5) having void (2) space operable to compress between fingertips reducing their width before being pushed through portals (11) of two logs (10) to hold the two logs together. Once in place, fasteners (1) are released so the tips (5) expand back to their original width, creating a significant interference with the portals (11) in each log wall so the logs (10) stay together. These fasteners (1) cannot be easily removed from the logs (10) until they are again squeezed and purposely removed.

[0025] The portals (11) which pass through the log wall's exterior sides allow fixed, pivoted, and/or removable connection between two logs (10). A “Fixed” connection is defined as one which is expected to or does cause breakage to one of the parts described when removed. “Removable” is defined as able to connect and disconnect repeatedly (>6 times) without causing breakage to a connector piece or parts being connected. “Pivoted” is defined as a linkage that allows a at least one degree of freedom of movement similar to a hinge between fastened logs or parts. While a string (40) or adhesive tape can alternatively be used to fasten the foam log extrusions to each other, this simple mechanical fastener (1) made of injection molded plastic provides a more convenient way to temporarily or removably attach the extruded logs (10) to each other for easy construction of playsets and other structures.

[0026] Several views of one example of the fastener (1) is seen in FIGS. 4a-c. Fastener (1) with tips (5) designed to pass through a portal (11) of a log or logs (10). The voids (2) may be arrow shaped tips (5) and in some embodiments have an eyelet at each tip (5) of the fastener (1) provide a place to run a string (40) (FIGS. 5 and 6) through fastener's voids (2). The string (40) may be used to bend and hold bent a log (10) in a curved shape.

[0027] The fastener (1) has a reduced neck (3) adjacent to the arrow shaped tips (5) so when they are compressed and passed through portal (11) in the log (10) and released, the tips (5) seat themselves inside the portal (11) in the log (10) so they cannot be easily removed without again compressing the fastener (1). To compress the fastener (1) there may be pads (4) at the ends of a center rib operable to be pressed together between fingertips.

[0028] In an embodiment log (10) or logs have wedge shaped apertures (12). The wedge shaped apertures may be created by cutting and removing this wedge shaped piece of log from the log (10) as seen in FIGS. 5 and 6. The wedge shaped apertures (12) are operable to allow the log (10) to bend even further, and as noted the log (10) may be held in place by a string (40) that passes through multiple fastener (1) through the void (2) eyelets in tips (5). Using curved logs with straight logs, more complex forms can be built with the logs (10). Like timbers in the hull of a ship the curved logs can be used to form the hull while straight logs can form the mast and other features. Adhesives such as hot melt, adhesive tape such as packing tape, and/or a string (40) passed through fasteners (1) can hold a log (10) in curved shape to aid the construction of boats and other playsets that have curved timbers in real life. Tips (5) may also provide attachment points for an assortment of accessories including: holiday lights, roof sections, family pictures, or curtains.

[0029] For safety reasons, the molded plastic fasteners (1) are large enough to pass the toy industry's Small Part Test to prevent swallowing of the part by children. Toy industry studies have established that a diameter greater than 1.25″ achieves a level of safety acceptable in toy design to pass the above test. The fastener (1) is also long enough to pass through the portals (11) in the walls of two stacked logs (10) so it can hold the logs in place until the fastener (1) is again compressed and removed from each log (10).

[0030] In an embodiment of the construction playset many connector designs (not shown) having apertures operable to work with fasteners (1) allow attachment of logs (10) to each other in specific orientations such as parallel to each other, end to end, or at right angles to each other. These specialized connectors are operable to work together with squeezable fastener (1).

[0031] The logs (10) may be cut by an angled miter (30) as seen if FIGS. 7 and 8a-f. A toy saw (not shown) is optionally used to cut logs (10). The toy saw will cut a log (10) by bursting the walls of thousands of soft plastic bubbles in the foam logs (10). This method of cutting logs (10) results in minimal mess, (i.e. such as saw dust with other materials), and also makes accidentally cutting a finger very difficult, since a non-sharp edge is all that is needed to cut logs (10) with the toy saw. An angled miter (30) may be operable to guide a toy saw. A log (10) may be cut to a certain length or angles cut into the log. The angles may be wedges of the foam log (10) that after removal form apertures (12) operable to bend the logs to a predictable angle and the log may be held there.

[0032] Miter guides (31) are rotatably attached to a miter base (33) upon which the log (10) may be placed to cut. The two miter guides (31) are attach adjacent to the miter base (33). The miter guides (31) each have teeth (34) which engage with each other and are operable to move miter guides (31) to pivot away from and towards each other at the same time to the same angle. The miter guides (31) provide a resting angle for the toy saw blade so it can be used to cut wedge shapes from the logs (10) for removal. The cuts converge from opposing directions assisted by the miter guides (31) and the cuts that are symmetrical about the vertical forming a wedge-shaped piece of foam to be removed from the log (10). The miter guides (31) may be held or locked in place once they are adjusted to the desired position by a cam lock (32). Optionally, a compass like indicator (35) can be used so the angle between the guides can be accurately quantified for repeatable results. The miter guides (31) can be held in place with the use of detents, channels or other interference designs in base (33) that prevent guides (31) from having a full range of motion. In this way, the straight log (10) can now bend to a predictable angle with this wedge removed. Removing multiple wedge shapes allows angles, curves and even full circles resembling a wheel to be formed with an originally straight log (10).

[0033] These playsets may allow for inside, outside and water-play, allowing children to build their own designs with a soft material that can be cut, bent and fastened together to create a wide range of entertaining playsets. This playset or toy provides children not only excitement during the construction phase, but also a durable, imaginative educational toy that withstands rain, wind and intense sunlight just like existing rotomolded playhouses because the foam logs are also made of polyethylene exactly like the rotomolded products. This toy allows children to develop by thinking three dimensional thoughts creating and building playsets with soft, large diameter foam extrusions.

[0034] This toy dramatically reduces the amount of plastic needed to build to a playhouse by roughly 85% so the resulting playhouses are much more environmentally friendly and all of the logs are 100% recyclable.

[0035] Building playsets in the real world may be assisted by augmented reality software on a computer platform such as an iPad, so children can build and play with their playsets online, on their own computer, as well as in the real world. The software will allow children to see and walk around their designs viewing their playsets on their computer or phone screens full size as if they already existed in the real world and may include augmented reality software. The program will also provide step by step instructions for constructing the playsets in the real world based on how the children constructed them in the virtual world. The program will provide the optimal list of log cuts so children can make their designs using a minimum number of logs (10) and fasteners (1).

[0036] While the disclosed technology has been taught with specific reference to the above embodiments, a person having ordinary skill in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the disclosed technology. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Combinations of any of the methods, systems, and devices described herein above are also contemplated and within the scope of the disclosed technology.