The disclosed subject matter pertains to building blocks. In particular, the subject matter pertains to plastic foldable blocks.

References considered to be relevant as background to the presently disclosed subject matter are listed below:

• US3,368,316
• US2003/029119
• US2008/292830

Acknowledgement of the above references herein is not to be inferred as meaning that these are in any way relevant to the patentability of the presently disclosed subject matter.

Building blocks made of various types of materials, such as plastic, wood, cardboard and even foam are known in the art. The blocks are used for different purposes, such as for building toys and toy structures, for erecting various structures for indoor or outdoor use, such as furniture structures.

For example, US3,368,316 is directed to a hollow building block foldable from a blank of cardboard like sheet material for use as a toy and decorative purposes and the like. The blank comprising a central panel having opposed pairs of parallel edges, side panels of similar shape to each other respectively foldably connected to one pair of opposed edges of the central panel, end panels of similar shape to each other and of the same width as the side panels foldably connected to the other pair of the opposed edges of said central panel, end flaps foldably connected to the opposite ends of each of the side panels and of similar shape to the end panels and overlying the end panels when the side and end panels are folded perpendicularly to the central panel from the same surface thereof and when the end flaps are folded to extend perpendicularly from the central and side panels, similar ears projecting from corresponding outer edges of the end flaps when so folded and overlying each other within the planes of the flaps. Also comprising means to secure said block in folded and erected position, and means including locking flaps foldably connected to the outer ends of the end panels and having openings complementary in shape to said ears. The locking flaps are folded over overlying pairs of the ears the latter are received through the openings to maintain the block in folded condition with the cars projecting perpendicularly from the face of said blocks which is opposite the central panel, the central panel having slots therein adjacent opposite edges thereof of a size adapted to receive the ears projecting from similar blocks when placed upon the central panel of the first-mentioned block to permit the interlocking of such blocks against relative lateral movement parallel to the central panels.

US2003/029119 is directed to a system for modular construction provided by interconnectable and stackable polymeric blocks having end and side walls connected to a top wall, and exterior and interior cylinders. The exterior cylinders are matable with the interior cylinders of a connecting block, and apertures in the top wall allow for re-bar, conduit or installation of insulation. Raised ribs located adjacent to the top wall contact the connecting block to further enhance stability of the erected structure.

US2008/292830 is directed to a method and apparatus regarding lightweight but robust multilayered foam furniture pieces. The furniture pieces include a foam base, a polymeric solidifying layer, and a decorative layer. The decorative layer can include an acrylic-based surface finish and/or one or more decorative pieces, tiles, or other variously shaped objects attached to the primer layer and/or part of the decorative layer.

EP 1 629 872 A1 relates to a toy building block comprising a hollow three-dimensional structure with a plurality of faces and provided on at least one of said faces with engagement means able to co-operate with complementary engagement means of another block. The three-dimensional structure is formed by a pliable element with a perimeter whose shape corresponds to the planar development of the block. The pliable element is provided with between adjacent portions forming the faces of the three-dimensional structure. Snap-in fastening means are provided for fastening each of said faces to an adjacent face of the three-dimensional structure.

GB 2 224 664 is directed to a blank for forming a block suitable for educational and play uses comprises a base, sides and top formed with each side attached to an edge of the base by a so-called "living hinge" and the top so attached to an edge of one of said sides. The other said sides have edge formations that engage complementary formations of the top to hold them together in the assembled block. Interengaging formations are also provided. The surfaces which will form the outside of the block have formations permitting blocks to be releasably connected.

CA 1 153 890 A1 describes a hollow form building block useful for toys as a constructional block for play houses, forts, and the like, which is formed of inexpensive sheet material such as corrugated cardboard. The block element is a hollow-form, polyhedron that is provided with end walls, one of which has a polygonal aperture and the other of which has a coacting polygonal raised rim that is formed by folded tabs cut from the end wall and coacting tabs folded from an underlying end wall. The raised rim coacts with the apertures of other block elements to provide element-to-element interconnecting means and the raised rim also functions to secure the hollow-form block structure of the assembled, folded block element.

The presently disclosed subject matter is directed to a three dimensional building block comprising a plurality of integrally hinged panels constituting the block body, the body comprising at least three panels constituting at least two side walls and at least one functional wall, the functional wall comprising at least one coupling element; the building block further comprising two end walls wherein the block body is configurable between a disassembled, substantially flat configuration, and an erected configuration of a generally three dimensional hollow block body with the end walls configured to detachably attach to the open ends of the hollow block body.

The term 'living hinge' (also referred to as an 'integral hinge'), as used herein in the specification and claims denotes a flexible hinge portion. In accordance with certain embodiments the hinge is made from the same material as the side wall and the lid articulated it connects thereto, and is typically thinned or cut to allow the rigid pieces to bend along the line of the hinge.

In accordance with the disclosed subject matter there is also disclosed a system of stacked building blocks provided in a knocked down configuration, each building block comprising:

1. a. a block body, the body comprising four hingedly articulated panels constituting two side walls and at least two functional walls, each of the at least two functional walls comprising at least one coupling element;
2. b. two end walls;

Any one or more of the following properties, designs, features and configurations can be associated with the building block structure subject of the presently disclosed subject matter, separately or in combinations:

• The building block can be stacked over a building block of a-like configuration;
• An array of smaller building blocks can be stacked over the building block having larger or different dimensions;
• The living/integral hinge connecting the panels of the building block can be continuous or interrupted to thereby define resilience thereof;
• The end walls of the building block are detachably attachable to the body structure of the building block;
• The detachment of any one or both of the end walls can facilitate access into the hollow space formed by the walls of the structure;
• The building block can comprise four panels connected through a living hinge forming a polygonal sheet, the panels correspond to the two side walls, the top wall and the bottom wall which in their folded, erected configuration form the hollow block body, and wherein, at least one of the panels is a functional wall, comprising at least one coupling element;
• The coupling element can be a stud or a stud receiving cavity; one functional wall can comprise both types of the coupling element;
• The polygonal sheet comprises two working edges interlockable when the sheet is erected to form the three-dimensional structure;
• At least part of the building block panels, can comprise raised longitudinal ribs, e.g., on the side walls, to impart rigidity and strength to the erected structure such that when erected the ribs extend such as to allow the block to withhold more weight when load is placed thereupon.
• The building block can comprise raised ribs, which constitute part of a movement preventing mechanism which imparts further characteristics of strength and inhibits unintentional movement and collapse of the side walls under weight/force;
• The building block can comprise one or more apertures to allow ventilation;
• The building block or parts thereof can be made by injection molding from plastic material;
• One or more building blocks can be stacked and/or interconnected to form furniture items;
• The building block can comprise four panels integrally hinged and have a parallelepiped configuration;
• The panel constituting the top wall of the building block can comprise outwardly protruding coupling studs and corresponding receiving cavities on the panel corresponding to the bottom wall;
• The coupling studs can be configured to interlock with the receiving cavities of the like building block;
• The coupling studs and the respective receiving cavities can extend coaxially;
• At least one side wall of the coupling stud can be slightly slanted, e.g. for extraction purposes;
• Any one of the studs or the cavities (or both), can be fitted with friction increasing elements and/or locking elements to prevent unintentional disengagement between the studs and the receiving cavities;
• The friction increasing/locking elements can be one or more outwardly protruding elements on at least one of the stud wall face designed to increase friction when received in the receiving cavities and to lock the studs within said cavities in a firmer and stronger manner;
• The studs can have a rectangular cross section and the cavities have a respective shape, adapted to receive the stud;
• At least part of an outer surface of the building block can be fitted with friction increasing elements;
• At least one of the connecting elements can be configured with a snap-type arresting arrangement for engaging and arresting over a corresponding locking notch configured at a like building block;
• The building block can he provided with UV-protective layer;
• The side walls can be fitted with restraining members adjacent its edges; the restraining members can be configured to abut the inner side of the hollow body when in the erected configuration so as to impart the structure with strength.

In order to better understand the subject matter that is disclosed herein and to exemplify how it can be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

• Fig. 1A is a perspective top view of a building block in accordance with one example of the disclosed subject matter;
• Fig. 1B is a perspective side and bottom view of a building block of Fig. 1A;
• Fig. 1C is a bottom view of a building block of Fig. 1 A;
• Fig. 2A is a cross sectional perspective view of a building block of Fig. 1A taken along lines A-A;
• Fig. 2B is an enlargement of an area marked S in Fig. 2A;
• Fig. 3 is a perspective view of a building block in accordance with the disclosed subject matter in a disassembled configuration;
• Fig. 4A is a perspective view of a bottom side of the building block illustrated in Fig. 3 devoid the side walls;
• Fig. 4B is a top view of a top side of the building block illustrated in Fig. 3 devoid the side walls;
• Fig. 5 is a bottom perspective view of a side wall of the building block illustrated in Fig. 3
• Fig. 6 is an enlarged, perspective view of an area marked I in Fig. 4A;
• Fig. 7A is a side perspective view of stacked building blocks in accordance with the disclosed subject matter, the building blocks being in their disassembled, unfolded configuration;
• Fig. 7B and 7C illustrate a stack of twenty building blocks in accordance with the disclosed subject matter, the building blocks being in their disassembled, unfolded configuration and arranged to minimize package and transportation space, with Fig. 7B illustrating a free standing stack and Fig. 7C illustrating a packing in a box stack;
• Fig. 8A is a side view of a block of Fig. 1 shown in a cross section taken along the lines B-B;
• Fig. 8B is an enlarged view of the area marked II in Fig. 8A;
• Fig. 9 is a perspective top view of the bottom side of a block in accordance with another example of the disclosed subject matter, in a disassembled configuration and devoid the side walls;
• Figs. 10A and 10B illustrate a furniture set and a plant holder constructed using the building blocks in accordance with the disclosed subject matter;
• Figs. 11A-11C illustrate two blocks of different lengths in interlocked configurations;
• Fig. 11D illustrates a cross section of two stacked blocks of Fig. 11C taken along the lines A-A;
• Fig. 12 is a cross sectional view of a block in accordance with another example of the disclosed subject matter, the block having a shape of a trapezoid cube;
• Fig. 13 is a cross sectional view of a block in accordance with yet an example of the disclosed subject matter, the block having a shape of a triangular prism; and
• Fig. 14 is a cross sectional view of a block in accordance with yet another example of the disclosed subject matter, the block having outwardly curved sidewalls.

The disclosed subject matter pertains to building blocks which are interlockable with like blocks. The building blocks in accordance with an example of the disclosed subject matter are made by injection molding from plastic material. The building blocks can be used for construction of various structures such as furniture items, seen for example in Fig. 10A, stationary structures such as a separation wall, or plant holders seen in Fig. 10B.

In accordance with the disclosed subject matter, the building blocks are configured to deploy between a disassembled substantially flat configuration and an erected configuration of a generally three dimensional structure.

The disclosed subject matter allows construction of modular structures comprising a plurality of blocks in accordance with the disclosed subject matter. Thus, for example, a plurality of the building blocks can be used to construct a plant holder and same blocks can be used to construct a table, sofa, armchair, etc.

Attention is first directed to Figs. 1-2 illustrating a building block generally designated 100 in accordance with one embodiment of the disclosed subject matter. The building block 100 has a hollow, generally parallelepiped configuration (cuboid in this case) and comprises two opposite side walls 110A and 110B, a top wall 120, a bottom wall 125 (seen best in Fig. 1B), constituting a body 105 of the block 100, and two end walls designated as 115A and 115B. The top wall 120 of the block 100 comprises outwardly protruding coupling studs 130 and receiving cavities 140 on the bottom wall 125. The coupling studs 130 are configured to interlock with the receiving cavities 140 of the like block 100. Such interlocking can be seen in figures 11B through 11D. In accordance with this specific example the coupling studs 130 and the respective receiving cavities 140 extend coaxially as best seen in Figs. 1B, 2 and 11D. At least one side wall of the stud 130 is slightly slanted to facilitate removal thereof from the mold and in use, to facilitate interlocking with the cavity 140. The studs 130 are further fitted with outwardly protruding longitudinal element 132 on each face thereof designed to increase friction when received in the receiving cavities 140 and to lock the studs 130 within said cavities 140 in a firmer and stronger manner. It will be appreciated that such outwardly protruding element is an optional feature and other friction increasing/locking elements can be utilized to achieve the same function. The protrusion can thus range in size, i.e. length of the protrusion measured outward from the outer wall of the stud 130, from 0-50mm, from 0-10mm, from 0-3mm depending on the required clamping force. Such protrusions can be configured on any number of faces of the stud. Alternatively, the studs can be free of any such elements.

The height h of the coupling stud 130 is equal to or less than the depth H of the receiving cavity 140 so as when the two like blocks 100 are interlocked the studs 130 are substantially received within the cavity 130 so as to form a unitary structure comprising the two blocks 100 substantially devoid of any space therebetween. The studs 130 in accordance with this specific example have a rectangular cross section and the cavities 140 have a respective shape each adapted to receive the stud 130. As seen in Fig. 1C, the cavity further comprises a recess in its walls configured for snap engagement of the outwardly protruding element 132 fitted on the studs 130. The exemplified block 100 comprises only four studs 130 with such protrusions 132, disposed at the corners of the top wall 120, however it will be appreciated that in accordance with the disclosed subject matter any number of studs 130 can be fitted with such elements.

While the current example is directed to a building block 100 comprising two rows of four coupling studs 130 each and respective two rows of four receiving cavities 140 the vast number of possible combinations is envisioned by the presently disclosed subject matter, e.g. block 200 comprising only two studs 230 in each row as seen in Fig. 9 in its flat, disassembled configuration and Figs. 11 in an assembled, configuration fitted over the block 100. It is also to be understood that the modularity of the structures constructed from the blocks is facilitated as seen in Fig. 11. Further, the blocks 100,200 can be interlocked not necessarily when fully coextending but rather one block can be seated over a like block through part of its studs.

It will be appreciated that the block can have any dimensions desired for the specific design and can be shaped to conform to a particular construction application thus for example rather than having cuboid configuration as seen in Fig. 1A it is appreciated that the building block can have a shape of a pyramid or a triangle cross section. Such shapes are seen for example in Figs 12-14 , where cross sections of the blocks 500, 300, 400, respectively are illustrated where features similar to those of block 100 are identified by same numerals, upped by 400, 200 and 300, respectively and will be discussed herein after.

The end walls 115A and 115B of the block 100 exemplified in Fig. 1A are detachably attachable to the block's body structure 105. In accordance with this example the end walls 115A and 115B are snap fitted to the open edges of the structure 105 as will be further discussed. It will be appreciated that other solutions can be employed to achieve the same result. Alternatively the one or both of the end walls 115A and 115B can be permanently attached to the body 105.

The detachment of any one or both of the end walls 115A and 115B can facilitate access into the hollow space formed by the side walls of the structure, e.g. for storage. As best seen in Fig. 1B, the receiving cavities 140 on the bottom wall 125 of the block 100 further comprise apertures 142. Such apertures allow ventilation of the block's 100 interior. It will be appreciated that such apertures 142 are optional. The blocks can be used to build structures for outdoor use. To provide such structures, e.g. a separation wall, with sturdiness and ability to withstand movement due to weather conditions or incidental displacement might be filled with weight increasing material such as sand, stones, liquid, etc. An outer layer of the block at least partially can be covered with a UV-protective layer or such material can be integrated into the block material.

Turning now to Figs. 3 through 6, a discussion will be provided on the structure and assembly of the building block 100 in accordance with an example of the disclosed subject matter. Fig. 3 illustrates all elements of the building block 100 illustrated in Fig. 1A in its collapsed configuration. Fig. 3 illustrates a polygonal sheet comprised of four integrally formed panels connected to each other through their respective edges by means of an integral hinge 134 (i.e. living hinge which can also be constituted e.g. by a thinned section of the material as seen in Fig. 6 or fold enabling perforations in the material, not shown). The panels correspond to the side walls 110A and 110B, the top wall 120 and the bottom wall 125 which in their folded, erected configuration form the hollow block body 105. Also shown are the two end walls 115A and 115B which are configured for coupling to the polygonal sheet 105 when in its erected folded configuration.

Fig. 4A provides an illustration of the polygonal sheet illustrating its four panels 110A, 120, 110B, and 125. Seen in a perspective bottom view of the sheet is an inner side of the building block which shows the two working edges T1 and T2 of the polygonal sheet. These edges T1 and T2 are interlockable when the sheet 105 is erected to form the three-dimensional structure seen in Fig. 1A. In accordance with this embodiment the two working ends are configured for snap fitting one within the other. The working edge T1 is associated with the bottom wall 125 while the working edge T2 is associated with the side wall 110A. The working edge T1 is configured with a curved protrusion 127 adapted to be received within a slot 129 provided on the edge T2 and lock therein, e.g. by snap fitting. When the two edges T1 and T2 arc brought together, the integral hinges come into operation to facilitate fold therealong such that the two side walls 110A and 110B are supported over the bottom wall 125 panel and support thereon the top wall panel 120.

The panels are provided on the bottom side with raised ribs to impart these with rigidity. As seen in this figure raised longitudinal ribs are provided on the side walls 110A, 110B to impart rigidity and strength to the erected structure such that when erected the ribs extend along the axis X (shown in Fig. 1A) thus configured to allow the block to withhold more weight when load is placed thereupon. Further ribs are provided on the bottom side of the top wall and the bottom wall as seen in Fig. 4A. The ribs of these panels are crossed surrounding each of the studs and the receiving cavities thereon, respectively. The outer edges of the top wall panel and the bottom wall panel adjacent the integral hinges are provided with further raised longitudinal ribs 158. In accordance with this example, the ribs 158 are connected to the transverse ribs extending along these panels. These ribs 158 constitute part of a movement preventing mechanism which imparts further characteristics of strength and inhibits unintentional movement and collapse of the side walls under weight/force. The raised ribs 158 are configured for interlocking vis-à-vis the raised rib 155 on the side wall 110A and 110B which extend perpendicularly to the ribs 158 when the block is in its disassembled flat configuration. The end 155A of the rib 155 adjacent the integral hinge 134 is configured with a cut out section forming a shoulder, having dimensions configured to fit over the raised rib 158. The dimensions of the shoulder 155A are such that the height S of the rib 158 and the length L of the cut out section 155A are substantially the same so as for the shoulder to sit over the rib 158 and abut it in the event that force is exerted thereupon. Working configuration of this mechanism is best seen in Fig. 8B illustrating the shoulder 150A sited over the raised rib 158 and supported thereupon.

With reference to Fig. 5, end walls 115A and 115B will not be described. As indicated hereinbefore, each end wall 115A and 115B is configured for attachment to the open ends of the hollow body 105. The attachment in accordance with the illustrated example is through snap fitting facilitated by a receiving cavity 114 fitted at the edges of the end wall and corresponding protruding curved edges 112 (best seen in Fig. 2B) at the outer ends of the panels 110A, 120, 110B, 125. It will be appreciated that whilst in the described examples the edges 112 are continuous along the ends, other configurations can be employed, such as non continuous edges, staggering edges etc. The side wall is fitted with raised reinforcing ribs 150 disposed at its bottom side 154 and restraining members 152 adjacent its edges. The restraining members 152 are configured to abut the inner side of the hollow body 105 when in the erected configuration so as to impart the structure with further strength.

Fig. 7A illustrates a plurality of blocks 100 in their disassembled, knocked down configuration stacked one over the other. As can be appreciated from this illustration, the block bodies 105 are stacked one over the other with the sidewalls 115A and 115B arranged therebetween to minimize the space for packing and transportation purposes.

Figs. 7B and 7C illustrate a stack 1000 of twenty building blocks 100 in a ten layer stack, the building blocks being in their knocked down, unfolded, configuration. The blocks are arranged as follows, allowing minimizing the size of a package for their transport, maximizing the use of the package space (e.g. as illustrated in Fig. 7C): the knocked down block body 105 is placed in the illustrated example face down (i.e. the surface facing outwards when in the erected configuration is facing down, although it will be appreciated that the other face of the block can face downwards) with the panel constituting the functional bottom wall 125 facing the outer end of the stack, seen at the left of the illustration, and the block of a similar configuration is placed adjacent (for the purposes of explanation, same elements of the block are identified using same numerals with added " ' "), however in a turned around, reversed configuration, such that the panel constituting the side wall 110A' is now overlapping the panel 110A, and the panel constituting the functional bottom wall 125' facing the outer, other end of the stack, seen in the right side of the illustration. The two end walls 115A and 115B and 115A' and 115B' arc placed over the intermediate panels constituting the side walls 110B and 110B' of the respective block body. The following in stack layers are arranged in a similar manner. As can be seen in each row the adjacent panels overlap (in this example one panel from each side) and in each column, the adjacent block bodies fully overlap over all four of its panels. As can be appreciated from Fig. 7B and 7C, the height H of the panel comprising the receiving cavity 140, the height h of the coupling stud and the panel it protrudes from and the height of the intermediate panels 110B with the end wall 115 placed the rover as well as the height of the two overlapping side walls 110A and 110A' are substantially equal, thus contributing to the stability of the stack 1000, with all possible gaps filled by the respective elements of the block. Thus, in each row, the two polygonal sheets 100 and 100' partially overlap over the panels 110A and 110A' and in each column, the two polygonal sheets fully overlap in both columns. Thus sheet 100 overlaps like sheet placed over in the same orientation and sheet 100' overlaps like sheet placed over in the same orientation over it.

It will be appreciated that the blocks can be arranged in a different manner and different stacking configurations are envisioned, mutatis mutandis.

Turning now to Figs. 12-14, Fig. 12 illustrates a block having a generally trapezoid cross section taken transversely, where the top wall 520 and the bottom wall 525 are parallel, and where the width W of the panel constituting the top wall 520 is broader than that of the bottom wall, having a width w. Fig. 13 illustrates a block 300, having a generally triangular cross section, where the side walls 310 A and 310B are of the same dimensions and wherein the functional wall 321 connecting the side walls comprise a plurality of studs 330 (only one is seen in this view) and a plurality of receiving cavities 340. Fig. 14 illustrates a block 400, similar to the structure of block 100 with the difference that the side walls 410A and 410B are slightly outwardly curved.