US20100130094A1 - Interlocking panel and kit of such panels - Google Patents

Abstract

A modular system for forming without tools a variety of 3-dimensional structures comprises panels (10), and connectors (13, 14), and locking bridging members (30) for assembling the panels (10) together in a desired configuration. The panels can be disconnected so that the erected structure can be disassembled with ease for future reuse. The system can be used to erect children's playhouses made of polymer materials, as well as in a large variety of other applications to create 3-dimensional objects requiring rapid positive construction without tools.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This Application is a Continuation Application of PCT Application No. PCT/CA2007/002098, filed on Nov. 20, 2007, which claims priority on U.S. Provisional Application No. 60/859,993, filed on Nov. 20, 2006, which is herein incorporated by reference.
FIELD OF THE INVENTION
• The present invention generally relates to an interlocking panel. More specifically, the present invention is concerned with a panel, in a panel building set, which can be locked and unlocked to another like panel.
BACKGROUND OF THE INVENTION
• Construction toys for children are commonly available and are comprised typically of 3-dimensional blocks having a brick-like appearance. Some such toys provide for interlocking between blocks, but due to their ungainly nature and/or small size, they cannot be made to enclose three-dimensional habitable spaces easily. Small interlocking blocks have been used to design and construct toys and shapes according to children's imagination, but these blocks are too small to create space enclosures cheaply or simply. For the same reason, these blocks cannot be used to create labyrinths, furniture, or other playthings at a scale which the child can play in.
• Space enclosures specifically designed for play use as children's toys are typically not designed for flexibility as a system that can produce enclosures of many shapes, but rather are typically designed for a single end use, are shipped disassembled to save space, and are erected at the end use location. As such, they provide less incentive for creative play than if they were able to be joined together easily to make space enclosures according to the imagination of the end user. Assembly methods of such space enclosures can vary from using tools to using hook and loop interlocking fabric (Velcro™) as in U.S. No. Pat. No. 4,964,249 or more complex assembly means, such as U.S. Pat. No. 5,544,870. The simpler assembly methods are generally used for single-purpose structures, while the more complex assembly methods do not lend themselves to simple assembly and disassembly by children.
• Use of foam blocks to make children's toy space enclosures is limited by cost, the need for space to store them, safety concerns related to flammability and hygiene, and the need to balance structural strength with compressibility, amongst other limitations.
• This present invention allows children to rapidly create safe 3-dimensional structures in a wide variety of shapes, including space enclosures, and to disassemble them and store the parts in a very small space. The design allows manufacturing them and distributing them at a relatively low cost, thus creating a new class of children's toy.
SUMMARY OF THE INVENTION
• It is therefore an object of the present invention to provide a system for joining modular panels without tools to form 3-dimensional structures and to disassemble them for future reuse. The panels can mate mechanically with one another, and may be made of multiple geometric shapes of three or more sides, allowing them to form an almost infinite number of forms when joined together in various ways.
• An aspect of the present invention is that assembly and disassembly of the panels is very easy and positive, so that panels sized for children's toys can easily be assembled by a child without the aid of an adult.
• It is further an object of the present invention to provide panels that are designed to be stackable for storage, and may be made in sections and materials optimized for structural strength, stiffness, light weight or other desirable mechanical properties in order to ensure fitness for use.
• Another object of this invention is to provide a fastening system allowing the positive assembly of panels at varying predetermined angles to each other in three dimensions, as well as the assembly of multiple panels emanating out of a common singular axis.
• In order to allow the builder to plan for and visualize the intended structure, a further aspect of this invention is an interactive web-based tool which allows the builder to build a virtual representation of the structure by selecting from a library of parts and assembling them on a computer. In its basic form, this tool would allow, for example, children to construct virtual space enclosures and other toys and would allow them to print construction plans for their creation. This software could as well allow the ordering of the pieces required to build the designed forms. In addition to having an interactive web based tool, it is an object of this invention to provide software that could be loaded onto a computer to provide a means of designing and building forms with the library of parts all in a virtual environment.
• According to the present invention, there is provided a system for joining panels to form 3-dimensional structures of a variety of shapes, comprising interlocking panels, connectors, and locking clips, wherein each panel has at least one connector on at least one of its edges, with said connector being adapted to provide a positive snap-in lock with a mating connector on an adjacent panel, such that the completed connection is able to swivel about a longitudinal axis of the connector to permit orienting the panels to a selected angle in relation to each other, and wherein adjacent parts of the panels may be fixed in place by one or more clips inserted along adjoining edges thereof to substantially prevent a rotation of the connectors.
• More specifically, in accordance with the present invention, there is provided a panel comprising: at least first and second edges; cooperating first and second connection elements provided on the first and second edges, respectively; the first and second connection elements of adjacent panels being adapted to snap connect together to interlock the adjacent panels while allowing for a relative pivot between the adjacent panels.
• More specifically, in accordance with the present invention, there is provided a kit for erecting 3-dimensional structures of a variety of shapes, comprising interlocking panels, connectors, and locking clips, wherein each panel has at least one connector on at least one of its edges, with said connector being adapted to provide a positive snap-in lock with a mating connector on an adjacent panel, such that the completed connection is able to swivel about a longitudinal axis of the connector to permit orienting the panels to a selected angle in relation to each other, and wherein adjacent parts of the panels may be fixed in place by one or more clips inserted along adjoining edges thereof to substantially prevent a rotation of the connectors.
• The foregoing and other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of an illustrative embodiment thereof, given by way of example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• In the appended drawings:
• FIG. 1 is a perspective view of a panel according to a non-restrictive illustrative embodiment of the present invention;
• FIG. 2 is a vertical cross-sectional view of the panel ofFIG. 1;
• FIG. 3 is a fragmentary view of two panels similar to the panel ofFIG. 1, illustrating a pair of C-shaped members and a pair of corresponding bars, in an unlocked position thereof;
• FIG. 4A is a front view of two panels, similar to the panel ofFIG. 1, assembled together in a locked position;
• FIG. 4B is a schematic cross-sectional view taken along line A-A ofFIG. 4A, showing the panels in the unlocked position;
• FIG. 4C is a cross-sectional view taken along line A-A ofFIG. 4A, now showing the panels coplanar in a locked position;
• FIGS. 5A and 5B are cross-sectional views similar toFIG. 4C, but showing the two panels at various angles one with respect to the other;
• FIG. 6A is a perspective view of a bridging member, according to an illustrative embodiment of the present invention;
• FIG. 6B is a top plan view of the bridging member ofFIG. 6A;
• FIG. 7A is another fragmentary perspective view of the bridging element ofFIG. 6A;
• FIG. 7B is a cross-sectional view taken along the line B-B ofFIG. 4A, showing the bridging member ofFIG. 6A engaged to two adjacent panels ofFIG. 1;
• FIG. 8 is a fragmentary enlarged view of a corner of the panel ofFIG. 1, illustrating a raised rib configuration;
• FIG. 9A is a perspective view illustrating the bridging member ofFIG. 6A before being inserted into two raised rib configurations of two panels ofFIG. 1;
• FIG. 9B is a view similar toFIG. 9A but showing the bridging member after having been engaged to the two raised rib configurations of two panels;
• FIG. 10 is a front elevational view of a flat wall made from four interlocked panels ofFIG. 1;
• FIG. 11 is a perspective view of a variant of the interlocking system ofFIG. 3, that is male and female connector elements herein shown in an unlocked position thereof, according to an illustrative embodiment of the present invention;
• FIG. 12A illustrates the male and female connector elements ofFIG. 11, just before being engaged together;
• FIG. 12B illustrates the male and female connector elements ofFIG. 11, engaged to one another ;
• FIG. 13A is a fragmented front elevational view of a female connecting element and a male connecting element, the latter having flanges on which are mounted center guiding posts protruding outwardly therefrom, according to a further illustrative embodiment of the present invention;
• FIG. 13B is a schematic representation of an assembly of four panels being interlocked about a same axis; and
• FIG. 13C is a cross sectional view ofFIG. 13B.
DETAILED DESCRIPTION OF THE INVENTION
• The present invention relates to panels that can be connected by means of a snap-on connection so as to form various shapes and structures, including 3-dimensional structures. The panels can be manually assembled and disassembled. The panels can be provided, for example, with joiner parts, lockable hinge-type mechanisms and bridging elements.
• A panel for use in a panel building set, according to non-restrictive illustrative embodiments of the present invention, will now be described. In a first embodiment, the panel comprises C-shaped female and bar male connection elements to allow two adjacent panels to be engaged together. In a second embodiment, the panel comprises further male and female connection elements, the panel of the second embodiment being otherwise similar to the panel of the first embodiment.
• It is to be noted that the illustrative embodiments each feature a panel having four equal sides or edges; however, it is understood that the panels may have three edges or more, which may be of equal or different lengths.
• Referring now toFIGS. 1 and 2, apanel10 is described. Thepanel10 generally has the form of a square having fouredges80₁,80₂,80₃and80₄of equal length.Panel10 comprises a concentric, centralsquare portion12, theedges90₁,90₂,90₃and90₄of which are parallel to theedges80₁,80₂,80₃and80₄ofpanel10. Centralsquare portion12 is slightly convex, as can be seen inFIG. 2. Asquare frame16, having anexternal boundary92, is formed on theedges90₁,90₂,90₃and90₄of the centralsquare portion12. A relatively flat perimeter flange orband11 is formed on theexternal boundary92 of thesquare frame16, theperimeter band11 being generally parallel to the centralsquare portion12. A raisedrib configuration15, which will be described in detail hereinbelow, is provided on each of the fourcorners310 of theperimeter band11.
• Theperimeter band11 comprises foursides11₁,11₂,11₃,11₄. The opposed sides11₁and11₂each comprise a pair of first snap-onconnection elements14 and14′; likewise, theopposed sides11₃and11₄each comprise a pair of second snap-onconnection elements13 and13′, which are configured to mate with a corresponding pair of the first snap onconnection elements14 and14′ of anotherpanel10.Openings19 and19′ (seeFIG. 3) are defined in theperimeter band11 about respectively each of the first snap-onconnection elements14 and14′, on bothsides11₁and11₂.
• Still referring toFIG. 3, the first snap-onconnection elements14 and14′ and the second snap-onconnection elements13 and13′ will be described in more detail.
• As previously mentioned,side11₁comprises twoopenings19 and19′, which are square-shaped and defined on one side by thesquare frame16, and on the opposite side, bybars17 and17′ of first snap-onconnection elements14 and14′, such that the longitudinal axes ofbars17 and17′ are coaxial with theedge80₁ofpanel10. Two protrudingblades21 and21′ project from respectively each end of thebars17 and17′, perpendicular to the axes of thebars17 and17′ and generally parallel to theperimeter band11.
• Side11₂is similar toside11₁; accordingly, a description of the former is similar to the above description of the latter.
• Side11₃comprises a pair of second snap-onconnection elements13 and13′ mounted on theedge80₃ofpanel10. The second snap-onconnection elements13 and13′ comprise respectively C-shapedmembers18 and18′ andfinger tabs23 and23′. C-shapedmembers18 and18′ generally each have the form of a cylinder cut longitudinally just over its half-way point and are made of a resilient material and provide the snap-on connection to thebars17 and17′ of theconnection elements14 and14′.Finger tabs23 and23′ are provided at free ends of the C-shapedmembers18 and18′, extend longitudinally therealong and protrude therefrom. C-shapedmembers18 and18′ are configured to accommodate respectively bars17 and17′ of anotherpanel10. Twoslots22 and22′ are formed onedge80₃, respectively at each end of second snap-onconnection elements13 and13′. Typically, thebars17 and17′ are substantially of the same length as the second snap-onconnection elements13 and13′.
• Side11₃is similar toside11₄; accordingly, a description of the former is similar to the above description of the latter.
• The pair of first snap-onconnection elements14 and14′ and the pair of second snap-onconnection elements13 and13′ are respectively positioned congruently onedges80₁or80₂, and onedges80₃or80₄, so that in a locked position, the pair of first snap-onconnection elements14 and14′ of onepanel10 is opposite to the pair of second snap-onconnection elements13 and13′ of anotherpanel10. Likewise,slots22 and22′ are located respectively opposite to protrudingblades21 and21′.
• It is to be noted that the pair of first snap-onconnection elements14 and14′ and the pair of second snap-onconnection elements13 and13′ are, in the present embodiment, symmetrical aboutcenter lines84 and86 ofpanel10.
• In the locked position of twoadjacent panels10, C-shapedmembers18 and18′ of onepanel10 snap onbars17 and17′ of theother panel10, such that the axes of the former are coaxial with the axes of the latter. In this manner, C-shapedmembers18 and18′ and bars17 and17′ form a pivot assembly about which the twopanels10 can pivot relative to one another.Slots22 and22′ ensure that protrudingblades21 and21′ are not obstructed while a pivotal movement is effected between bothpanels10.
• Bars17 and17′ are bordered bystructural ribs20 and20′, which merge into the protrudingblades21 and21′. These elements will be described in more detail hereinbelow.Structural ribs20 and20′ have a function of locating and stabilizingbars17 and17′. The distance betweenstructural ribs20 and20′ are such that thebars17 and17′ can be snapped into place in the second snap-onconnection elements13 and13′ with little or no lateral play, while allowing the second snap-onconnection elements13 and13′ to generally rotate freely aboutbars17 and17′.Openings19 an19′ allow a user's fingers to have access tobars17 and17′ and C-shapedmembers18 and18′. It should be noted thatopenings19 and19′ allow access to perform this function from both sides ofpanel10. Accordingly, assembling or disassembling a structure made ofpanels10 can be performed from both sides thereof.
• Finger tabs23 and23′ of the second snap-onconnection elements13 and13′, as shown inFIG. 3, can provide a gripping means so as to unsnap C-shapedmembers18 or18′ of onepanel10 frombars17 or17′ of anotherpanel10.Protruding blades21 and21′ protrude from perimeter edges80₁or80₂ofpanel10 at a distance Y. Similarly,finger tabs23 and23′ protrude from perimeter edges80₃or80₄ofpanel10, at a distance Y′, wherein Y=Y′, as shown inFIG. 3. In this manner,many panels10 can be assemble in a symmetric fashion. It should be further noted that whenmultiple panels10 are assembled together, for instance in a vertical fashion perpendicular to a support surface such as a floor, the lowermost row of panel perimeter edges80 will be supported at a same elevation with respect to the floor since the panels are supported by thefinger tabs23/23′ or the protrudingblades21/21′ and since Y=Y′.
• FIG. 4A illustrate two panels in a locked position, whereasFIGS. 4B and 4C are two sectional views therefrom, respectively in an unlocked position and in a locked position. Turning now toFIG. 4B, C-shapedelement18 is characterized by a slightly closed “C” shape, i.e. a transversal view of C-shapedelement18 is characterized by a perimeter which is slightly longer than that of exactly half a circle, the C-shapedelement18 extending at88, i.e. on a side thereof opposite thefinger tab23, beyond a median plane of the perimeter band/flange11. The slightly closed configuration of the “C” provides interference for the entry ofbars17 and17′. The material and thickness used to manufacture C-shapedmember18 and18′ are chosen so as to allow limited outward deflection thereof, and the deflection is to be resilient. The material can be advantageously a polymer resin. Accordingly, the interference between C-shapedmember18 andbar17 is overcome by a resilient deformation of C-shapedmember18.FIG. 4C illustrates abar17 in a locked position in a C-shapedelement18, wherein the latter accommodates and retain therein the former.
• Referring toFIGS. 5A and 5B, the twopanels10, which are in a locked position, can pivot relative to one another by an angle greater than 270°, the pivotal movement being only restricted by theperimeter band11 of a first panel's abutting againstbulge88 of anotherpanel10, wherein the extended span of the pivot angle advantageously favors both a flexibility of construction and an increased number of configurations.
• It is possible to assemblemany panels10, as shown inFIG. 10, so as to form aflat wall90. In order to stabilize thewall90, a bridgingmember30 in the form of a locking clip, as better shown inFIGS. 6A and 6B, is provided. Bridgingmember30 is inserted between adjacent panels both for bridging thepanels10 and for stabilizing them at a chosen angle as desired by the builder. More specifically, bridgingmember30 allows stabilizing two panels together from an acute angle to an angle of 180° therebetween, depending on the angle chosen for the bridgingmember30. Equally the bridging member can be made to have variable angles by way of, for example, a lockable hinge type mechanism, or a multiple bridging elements creating a center spoke type bridge system.
• Referring now toFIGS. 1 and 8, about eachcorner310 of thepanel10, there is provided on each side of the panel10 arib configuration15, which is generally characterized by two parallel and spaced “L”-shapedribs42 and43. In the present illustrative embodiment, each segment of the “L” is perpendicular to an edge ofpanel10. However, it is believed to be within the reach of one skilled in the art to envisage other configurations for a rib configuration, depending on the geometry of a panel. At each end, the “L”-shapedribs42 and43 open or flare (in a Y-shape) to form funnels44 and44′, so as to facilitate an insertion of the bridgingmember30 in a gap46 defined between the “L”-shapedribs42 and43. More particularly, facing, inwardly extending, end walls (or hooks)33 and33′ as well as50 and50′ of the bridgingmember30 can register snugly in the gaps46 ofrib configurations15 provided on adjacent corners of the twoconnected panels10 and on each side of thesepanels10.
• Referring now toFIGS. 6A,6B,7A andFIG. 7B, the bridgingmember30 will now be described in detail. Bridgingmember30 has a general configuration of two back-to-back elongated “C” shapes100 linked by a separatingwall32, the thickness of which is substantially equal to agap70 between two joinedpanels10, and as shown inFIG. 9A. Opposite to the separatingwall32, the “C” shapes100 each terminate with a hook-like end wall33 and50. As seen inFIG. 1, thepanel10 is characterized by slightly raisedrib configurations15 on all of its corners. Twoslot openings36 and36′ are defined at both ends of bridgingmember30 and define the open ends of the “C” shapes100. Typically, the width of theslot openings36 and36′ is generally the same as, or slightly less than, the thickness ofperimeter band11, so that when bridgingmember30 is in place, it provides a positive squeezing onperimeter band11 ofpanel10 by way of resilient deformations of the elongated “C” shapes100 of bridgingmember30. Advantageously, bridgingmember30 is made of a slightly flexible polymer material having a spring-like memory.
• Inside the elongated “C” shapes100, and opposite to slotopenings36 and36′, two corresponding slots orgrooves37 and37′ are defined in the separatingwall32. Similarly, the thickness ofslots37 and37′ is generally the same as, or slightly less than, the thickness orperimeter band11. For the purposes of rendering an example in this invention the bridgingmember30 is symmetrical about the center of the separatingwall32. As seen inFIG. 7A, hook-like end walls33 and50 have chamferedcorners39 and39′ so as to facilitate locating the bridgingmember30 on therib configurations15. Once inserted in therib configurations15, the bridgingmember30 allows for stabilizing two interlockedpanels10 at a chosen angle. The bridgingmember30 can further compriserigidifying ribs56. In the present illustrative embodiment, the two elongated “C” shapes100 are so configured as to bridge twopanels10 at an angle of 180°. However, different bridging elements can be used, such that the “C” shapes thereof are so configured as to bridge two panels at another angle, for angle.
• Referring now toFIG. 9A, the bridgingmember30 is used to stabilize two adjoiningpanels10 that are already connected via the first and second snap-onconnection elements14/14′ and13/13. Furthermore, the bridgingmember30 may serve to structure adjoined panels by solidifying and locking the rotating hinge joint between the panels.FIG. 9A illustrates two adjoiningpanels10, with the bridgingmember30 before it is inserted in the raisedrib configurations15.FIG. 9B illustrates the bridgingmember30 in place after it has been inserted in the raisedrib configurations15 of the two joinedpanels10. As it can be noted onFIG. 9B, the bridgingmember30 stabilizes the twopanels10.
• The bridgingmember30 can also be used to stabilize4 panels by first assembling two such panels as shown inFIG. 9B, and by then assembling2 more panels as shown inFIG. 10. Once assembled as such, the bridgingmember30 can be moved to the position shown inFIG. 10 where it straddles4 panels instead of just2. This will have effect of stabilizing4 panels.
• So as to control the registration and degree of travel of the bridgingmember30 once inserted, the inside of each of the “C”shape100 of the bridgingmember30 is further characterized by two rows ofribs51 which act as abutments against both sides of the perimeter flange/band11. A gap60 between the rows ofribs51 is essentially equal to the thickness of theperimeter flange11 onpanel10. This insertion of the bridgingmember30 can further be made to terminate in a over center snap detail where there is a hole ordepression41 on thepanel10 in the area of therib configuration15 and an opposingcentral rib52 and52′ found on the bridgingmember30 at the center of each “C”. Eachrib52 and52′ is the same height as allother ribs51 and further exhibits a protrusion38 substantially at the center point of therib52/52′, as shown inFIG. 7A, such that when the bridgingmember30 is inserted, termination of the insertion includes the snapping of the protrusion38 into the hole ordepression41. This snap assembly can be made to be removable so as to allow for disassembly.
• Therib configuration15 is found symmetrically on both sides of theperimeter band11 such that the back to back “C” configuration can be used to pin and hold thepanels10 at a given angle. As shown inFIG. 6A, the bridgingmember30 can be fashioned where theopenings54 and53 can be at various angles one to the other so as to control the various configurations of the inter-panel assembly.
• As shown inFIG. 9A andFIG. 9B, thepanels10 are easy to assemble without tools, and may even be assembled by children with limited motor skills. This fact taken into consideration, as well as the fact thatbars17 and17′ as well as C-shapedmembers18 and18′ must be assembled to each other, by way of a means of compressing thebars17 and17′ into the C-shapedmembers18 and18′, theopenings19 and19′ have been provided to allow the user's finger access to compress the elements together. It should be noted that this assembly procedure may be performed from either side of the panel in an unimpeded fashion. Thus, if the user has assembledmultiple panels10 together, the user may choose to assemble additional panels from the inside or the outside of the constructed assembly.
• In another illustrative embodiment, the snap-on connection is made by means of a male connecting element and a female connecting element, as will be described in detail hereinbelow, with reference toFIGS. 11,12A and12B. Typically, but not necessarily, the connecting elements are located about the center of an edge of a panel, although a longer edge can bear more than one connecting element.
• Referring now toFIG. 11, two similar resilientfemale connecting elements413 and413′ comprise respectively aflange419 and aflange419′ projecting normally from anedge450 of afirst panel410. Theflanges419 and419′ are terminated byexternal surfaces404 and404′ andinternal surfaces406 and406′, each being traversed respectively bycenter holes425 and425′. Opposite to thefemale connecting elements413 and413′, two similarmale connecting elements414 and414′ comprise respectively aflange418 and418′ projecting normally from an edge428 of anotherpanel410.Flanges418 and418′ are terminated byexternal surfaces400 and400′ andinternal surfaces402 and402′. Center guide posts411 and411′ project respectively from and perpendicular to theinternal surfaces402 and402′ ofmale connecting elements414 and414′. In a locked position, center guide posts411 and411′ are snap inserted respectively in center holes425 and425′. It is to be noted that the distance betweenflanges418 and418′ and the distance betweenflanges419 and419′ are chosen so as to provide an effective snap on connection when female connectingelements413 and413′ andmale connecting elements414 and414′ are in the locked position, i.e. thefemale connecting elements413 and413′ and themale connecting element414 and414′ are substantially opposite to one another. It is to be noted that, in order to facilitate the snap on connection, i.e. a snap assembly, it is possible to use a material and a thickness so that themale connecting elements414 and414′ are also resilient. Indeed,flanges419 and419′ may be permitted to elastically deflect when in contact withflanges418 and418′, or both pairs of connectingflanges419 and419′, and418 and418′, may be permitted to deflect elastically and independently when engaged together for snap assembly.
• To further facilitate a snap assembly,cylinders462 and462′ are interposed betweeninternal surfaces402 and402′ on the one hand, and center guide posts411 and411′ on the other hand.Cylinders462 and462′ each have an outerchamfered edge423 and423′, respectively.Chamfers430 and430′ are provided on theexternal surfaces404 and404′, whereinchamfers430 and430′ interfere with outer chamferededges423 and423′. In a locked position,cylinders462 and462′ are coaxially engaged in the center holes425 and425′, thus forming a hinge about which the two interlockedpanels410 can pivot. When thecylinders462 and462′ are snapped in place in the center holes425 and425′, chamfers430 and430′ slightly deflectflanges418 and418′ outwardly, andflanges419 and419′, inwardly, thus allowingcylinders462 and462′ to snap in place in the center holes425 and425′, as can be seen inFIGS. 12A and 12B.
• Yet to further facilitate assembling the connectingelements413,413′,414 and414′, chamfers430 and430′ compriseradial slots432 for facilitating guiding the center guide posts411 and411′ towards the center holes425 and425′ and thus engaging thecylinders462 and462′ therein.Slots432 also help prevent center posts411 and411′ from being deflected too far from their original positions.
• FIG. 12A illustrates the male414 and414′ and the female413 and413′ connection elements in an unlocked position, just before a locked position is reached, whereasFIG. 12B illustrates the same elements in a locked position.
• In the second illustrative embodiment, twopanels410 are being interlocked together about a common axis. However, it is to be noted that more than twopanels410 can be interlocked together about a same axis. Indeed, apanel410 with male connecting elements having center guiding posts on external surfaces of corresponding flanges, such that the center guiding posts are directed outwardly instead of inwardly, can engage into center holes of a corresponding female connecting element from the inside thereof. In this manner, apanel410 can be locked by engaging the center holes from the inside, whereas anotherpanel410 can be locked by engaging the center holes from the outside. As a result, three panels are interlocked together about a same axis. So as to facilitate multiple interlocking of panels, chamfers can be provided on both surfaces, internal and external, of the flanges corresponding to the female connecting elements.
• By varying the orientation of, and adding, chamfers and center guiding posts, as well as varying distances between pairs of two male/female connecting elements, it allows three or more panels to be interlocked about a same axis.
• Given by way of examples,FIGS. 13A illustratesflanges419 and419′ of a female connecting element, andflanges501 and501′ of a male connecting element, from which center guidingposts504 and504′ protrude outwardly.FIGS. 13B and 13C illustrate an assembly of fourpanels410, two of which have female connecting elements with flanges havingdouble chamfer elements503, the other twopanels410 having male connecting elements with outwardly-directed center guiding posts.
• The description of the present invention has been made with illustrative embodiments featuring panels that have a square shape. The illustrative embodiments have been given by way of example and it is to be noted that other shapes for the panels can be used. Indeed, a panel can be of any shape having three sides or more, the length of which can be variable relative to one another. This allows for fabricating structures based on principles of geodesic domes and related geometries, as well as, but not limited to, other Platonic and Archimedian polyhedra, or any other shapes that can conceivably be made from the system of panels, connectors, and clips described hereinabove.
• The connection elements are advantageously made from a material that allows repeated deflections to occur, without permanent deformation thereof. Thickness of the connection elements is chosen so as to obtain similar results.
• The area of thepanel10 circumscribed by theperimeter band11 may be flat, dished, embossed, or otherwise formed. This is more clearly shown inFIG. 2 by theconvex surface12 andsquare frame16. This convex surface serves to stiffen and strengthen the panel by increasing its moment of inertia and section modulus, respectively. In order to allow efficient stacking of the panels and to lower weight and cost, the thickness of the panel is normally kept as thin as is consistent with end use and method of manufacture. Stiffness and strength may also be adjusted by using different materials, adding or removing ribs, incorporating some other form of surface development, or adding to or subtracting from material thickness.
• Although not required for construction of the structures described in this invention, a further part of this invention is the creation of an interactive World Wide Web based tool which allows a builder to build a virtual representation of the structure by selecting from a library of parts and assembling them on a computer.
• In its simplest embodiment, this tool allows the builder to construct virtual space enclosures and other structures prior to selecting the pieces required to build them, and to print construction plans for their creation.
• Additionally, similar software used to allow a user to build structures via interaction on the World Wide Web, may be accessed by other software dissemination means such as a recorded containment means of said software which the user can then load onto a local computer for use, such as but not limited to an optically recorded digital memory disc.
• Furthermore, there is provided a packing box which acts as both a reusable storage box as well as transport dolly, and is adapted to the size and shape of the panels and connectors, and ergonomically suited to the end user's age, strength, and degree of manual dexterity. The box is resealable and can be comprised of wheels to facilitate transport and a handle to securely grip to transport it.
• Thepanels10 are stackable in a tight arrangement, including in the illustrated embodiment, a relative rotation of 90° between adjacent panels such that there is a substantial nesting of thebars17/17′ and the C-shapedmembers18/18′ of onepanel10 respectively with the C-shapedmembers18/18′ and thebars17/17′ of each of thepanel10 located under and above the aforementioned onepanel10.
• Although the present invention has been described hereinabove by way of non-restrictive, illustrative embodiments thereof, these embodiments can be modified at will, within the scope of the appended claims, without departing from the spirit and nature of the subject invention.

Claims (31)

1. A system for forming 3-dimensional structures of a variety of shapes, comprising at least two interlocking panels, connectors being provided for attaching together edges of adjacent panels, each said connector comprising first and second connecting elements provided on one and the other of a pair of panels, said first and second connecting elements being adapted to snap engage together for attaching said pair of panels together in an interlocked position of said panels, wherein in said interlocked position, said first and second connecting elements are adapted to allow said pair of panels to pivot relative to one another in said interlocked position.

2. The system as defined inclaim 1, wherein bridging members are provided, wherein each panel has at least one first or second connecting element on each of the edges thereof, wherein the panels in said interlocked position are able to swivel about a longitudinal axis of the connector to permit orienting the panels to a selected relative angle therebetween, and wherein adjacent parts of the panels may be fixed in place by one or more bridging member inserted along adjoining edges thereof to substantially prevent a rotation of the connectors.

3-11. (canceled)

12. The system as defined inclaim 2, wherein guides are incorporated on the panels to align bridging members in order to locate them on the panels and maintain alignment.

13. (canceled)

14. The system as defined inclaim 2, wherein openings are defined in the panel perimeter flange and at said connectors for allowing the panels to be assembled and disassembled either from the outside or the inside of a built structure.

15-21. (canceled)

22. A system for forming 3-dimensional structures of a variety of shapes, comprising interlocking panels, connectors, and locking clips, wherein each panel has at least one connector on at least one of its edges, with said connector being adapted to provide a positive snap-in lock with a mating connector on an adjacent panel, such that the completed connection is able to swivel about a longitudinal axis of the connector to permit orienting the panels to a selected angle in relation to each other, and wherein adjacent parts of the panels may be fixed in place by one or more clips inserted along adjoining edges thereof to substantially prevent a rotation of the connectors.

23-26. (canceled)

27. The system as defined inclaim 22, wherein the connectors and the clips or the bridging members incorporate locking mechanisms to ensure that once clipped together they cannot be inadvertently separated under normal use.

28-32. (canceled)

33. The system as defined inclaim 22, wherein guides are incorporated on the panels to align the clips or the bridging members in order to locate them on the panels and maintain alignment.

34. (canceled)

35. The system as defined inclaim 22, wherein openings are defined in the panel at said connectors for allowing the interlocking panels to be assembled and disassembled either from the outside or the inside of the built structure.

36-42. (canceled)

43. A kit for forming 3-dimensional structures of a variety of shapes, comprising at least two interlocking panels, connectors being provided for attaching together edges of adjacent panels, each said connector comprising first and second connecting elements provided on one and the other of a pair of panels, said first and second connecting elements being adapted to snap engage together for attaching said pair of panels together in an interlocked position of said panels, wherein in said interlocked position, said first and second connecting elements being adapted to allow said pair of panels to pivot relative to one another in said interlocked position.

44. The kit as defined inclaim 43, wherein bridging members are provided, wherein each panel has at least one first or second connecting element on each of the edges thereof, wherein the panels in said interlocked position are able to swivel about a longitudinal axis of the connector to permit orienting the panels to a selected relative angle therebetween, and wherein adjacent parts of the panels may be fixed in place by one or more bridging members inserted along adjoining edges thereof to substantially prevent a rotation of the connectors.

45. (canceled)

46. A panel for use with other panels for forming 3-dimensional structures of a variety of shapes, comprising:

at least first and second edges;

a first snap-on connection element about the first edge;

a resilient second snap-on connection element about the second edge, the second snap-on connection element being resilient;

wherein:

the first snap-on connection element of one of said panels is adapted to engage into the resilient second snap-on connection of another of said panels so as to form a snap-on connection interlocking said one panel and said another panel;

the snap-on connection enables a pivotal movement, about an axis, of said panel relative to said another panel.

47. A panel as defined inclaim 46, wherein a first opening is defined in the generally flat portion about the first snap-on connection element and a second opening is defined in the generally flat portion about the second snap-on connection element;

wherein the first and second openings enable manual access to respectively the first snap-on connection element and the second snap-on connection element, whereby the first snap-on connection element and the second snap-on connection element can be manually locked and manually unlocked.

48. A panel as defined inclaim 46, wherein:

the first snap-on connection element includes a bar;

the second snap-on connection element includes a C-shaped member; and

in a locked position, the C-shaped member snaps on the bar so that that the axis of the C-shaped member is coaxial with the axis of the bar.

49. A panel as defined inclaim 48, wherein the C-shaped member further comprises a finger tab.

50. A panel as defined inclaim 46, wherein:

the first snap-on connection element is a male connecting member;

the second snap-on connection element is a female connecting member; and

in a locked position, the male connecting member snaps in the female connecting member; and wherein:

the male connecting element comprises two flanges, each flange having an internal surface and a center post projecting normally from the internal surface; and

the female connecting element comprises two flanges, each flange having a center hole formed therein;

whereby in a locked position, the center posts of one panel engages respectively in the center holes of another panel.

51-53. (canceled)

54. A panel as defined inclaim 46, wherein:

the panel comprises a raised rib configuration about the intersection of two edges of the panel, the panel being in combination with a bridging member adapted to engage the raised rib configurations of a pair of adjacent panels for attaching the same thereat.

55. (canceled)

56. A panel as defined inclaim 54, wherein said bridging member includes a pair of opposed C-shaped members each adapted to receive therein part of one of the adjacent panels.

57. A panel as defined inclaim 56, wherein said C-shaped members include inner ribs for frictionally engaging the parts of the panels located therein.

58. A panel as defined inclaim 57, wherein at least one of the inner ribs is adapted to engage an aperture defined in the part of the panel.

59. A panel as defined inclaim 56, wherein said C-shaped members include end hook elements adapted to engage the panels, and wherein each said hook element is adapted to engage a groove defined by a pairs of ribs provided on the panel.

60-70. (canceled)

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