Toy construction block and method of manufacturing same

Abstract

A toy construction block for releasable connection to another toy construction block is disclosed. The toy construction block is made from a resilient material and has a first face having alternating ribs defining alternating channels therebetween. The ribs and the channels of the toy construction block are cooperatively adapted to snap to the ribs and channels of the other toy construction block to releasably secure the toy construction block to the other toy construction block.

1 . A toy construction block for releasable connection to another toy construction block, said toy construction block comprising: 
 a first face comprising a rib connected thereto, said first face defining a channel therein, said rib and said channel being cooperatively adapted to snap to said rib and said channel defined in said another toy construction block to releasably secure said toy construction block to said another toy construction block;    wherein said toy construction block is made from a resilient material.    
     
     
         2 . The toy construction block of  claim 1 , wherein said rib comprises a plurality of ribs and said channel comprises a plurality of channels.  
     
     
         3 . The toy construction block of  claim 2 , wherein each of said plurality of channels alternates with each of said plurality of ribs, wherein each pair of said plurality of ribs define one of said plurality of channels therebetween.  
     
     
         4 . The toy construction block of  claim 3 , wherein each rib comprises: 
 a) a neck connected to said first surface; and    b) a head connected to said neck.    
     
     
         5 . The toy construction block of  claim 4 , wherein each channel comprises a throat portion communicating with a receiving portion, said receiving portion being positioned interiorly of said throat portion, wherein said throat portion is narrower than said receiving portion and said head.  
     
     
         6 . The toy construction block of  claim 5 , wherein said head is adapted to be pushed through said throat portion into said receiving portion, said receiving portion of each channel is adapted to snugly receive said head, said throat portion being adapted to releasably secure said head of said rib in said channel.  
     
     
         7 . The toy construction block of  claim 6 , wherein said head and said throat portion are adapted to deform when said head passes through said throat portion.  
     
     
         8 . The toy construction block of  claim 7 , wherein said head compresses and said throat portion widens when said head passes through said throat portion.  
     
     
         9 . The toy construction block of  claim 7 , wherein said head defines at least one curved section, said curved section having a convex shape, said curved section being adapted to guide said head through said throat portion.  
     
     
         10 . The toy construction block of  claim 9 , wherein said at least one curved section comprises two opposing curved sections, each of said curved sections being adapted to contact a side of said throat portion.  
     
     
         11 . The toy construction block of  claim 9 , wherein said throat portion of a corresponding channel defines another two of said opposing curved sections, said another two of said opposing curved sections being adapted to guide said head into said throat portion.  
     
     
         12 . The toy construction block of  claim 11 , wherein each rib and each channel have a substantially identical shape.  
     
     
         13 . The toy construction block of  claim 3 , further comprising a second face, said second face defining said plurality of ribs and said plurality of channels.  
     
     
         14 . The toy construction block of  claim 13 , further comprising a pair of half-ribs connected to said second face and a pair of opposing planar side faces, each of said pair of half-ribs being positioned proximate to one of said pair of side faces.  
     
     
         15 . The toy construction block of  claim 14 , wherein each of said pair of half-ribs define a side surface, said side surface being coplanar with one of said pair of side faces.  
     
     
         16 . The toy construction block of  claim 15 , wherein one of said pair of half-ribs from said toy construction block and one of said pair of half-ribs from said another toy construction block are co-operatively adapted to be joined along said side surface and secured in said channel of a third construction block, thereby securing said toy construction block, said another toy construction block, and said third toy construction block.  
     
     
         17 . The toy construction block of  claim 16 , wherein said first face and said second face are in opposing relation.  
     
     
         18 . The toy construction block of  claim 17 , wherein said plurality of ribs defined in said first face comprises an even number of ribs.  
     
     
         19 . The toy construction block of clam  18 , wherein said plurality of channels defined in said first face comprises a center channel.  
     
     
         20 . A method of manufacturing a toy construction block from a substrate made from a resilient material, said toy construction block having a first face and a second face, said method comprising: 
 a) cutting said substrate along a first path, said first path defining said first face of a first block and said first face of a second block, wherein said first path defines a plurality of first ribs and first channels in said first face of said first and second blocks, wherein each of said ribs in said first block defines a channel in said second block and each of said channels in said first block defines a rib in said second block; and    b) cutting said substrate along a second path spaced apart from said first path, said second path defining said second face of said second block and said second face of a third block, wherein said second path defines a plurality of second ribs and second channels in said second face of said second and third blocks, wherein each of said ribs in said second block defines a channel in said third block and each of said channels in said second block defines a rib in said third block.    
     
     
         21 . The method of  claim 20 , wherein said first ribs and said first channels have a substantially identical first shape.  
     
     
         22 . The method of  claim 21 , wherein said second ribs and said second channels have a substantially identical second shape.  
     
     
         23 . The method of  claim 22 , wherein said first shape is different from said second shape.  
     
     
         24 . The method of  claim 23 , wherein said first face and said second face are cooperatively adapted for snug engagement therebetween.  
     
     
         25 . The method of  claim 24 , further comprising cutting said substrate transversely between said first and second path to form a first side face of said second block and a first half-rib on said second face of said second block.  
     
     
         26 . The method of  claim 25 , further comprising cutting said substrate transversely between said first and second path to form a second side face of said second block and a second half-rib on said second face of said second block.  
     
     
         27 . The method of  claim 26 , wherein said first path and said second path are substantially parallel.  
     
     
         28 . The method of  claim 20 , further comprising repeating steps (a) and (b).  
     
     
         29 . The method of  claim 28 , wherein said first path and said second path are cut in an alternating arrangement.