Claims:1. A cotton paper substrate, comprising of:
a material having 40 to 50 % by weight of the fiber cellulose of gossypium hirsutum cotton, 30 to 40% by weight of the fiber cellulose of pine wood pulp, 20 to 25% by weight tracheid cells, 2 to 4 % by weight of polyvinyl acetate.
2. The substrate as claimed in claim 1, wherein the mesh arrangement of its numerous layers is the interlinked combination of the fiber cellulose material present.
3. The substrate as claimed in claim 1, wherein the said substrate has a high inter-fiber strength, with the length of the fiber is 9-10 mm long.
4. The substrate as claimed in claim 1, wherein the said substrate comprises of starch in the range of 1 to 2 % by weight and atleast one dyeing agent.
5. The substrate as claimed in claim 1, wherein the dye is selected from the natural colours of marigold, saffron, caramel, cocoa, blueberries, raspberries, spinach, carrots and also including the approved synthetic dye like Allure Red E 129 , Tartrazine E 102, Sunset yellow E 110, Indigo carmine E 132.
6. A process for preparing the cotton paper substrate, comprising the steps of:
i. Ginning and separating gossypium hirsutum cotton to obtain its fiber;
ii. Grinding and Separating pine wood to obtain fibers;
iii. Cooking, Cleaning, Washing of the fibers in alkaline solution;
iv. Refining the fibers;
v. Optionally dyeing and drying the fibers;
vi. Placing the obtained fibers combined in mesh arrangement;
vii. Treating the arrangement with polyvinyl acetate;
viii. Pressing and drying them under hot press to form the required substrate.
7. The process as claimed in claim 6, wherein the alkaline solution comprises of sodium hydroxide as an active alkali, hydrogen peroxide, ethylene diamine tetraacetic acid and optionally using titanium dioxide.
8. A toy building block comprising of multiple sheets of the numerous layers of the interlinked fibers combined in a mesh arrangement of the said cotton paper substrate, starch and atleast dye or magnetic material or both.
9. The toy building block as claimed in claim 8, wherein the said toy building block can be constructed to be having blank, single and/or multi coloured block with a variety of vibrant color tones; hues and shades.
10. The toy building block as claimed in claim 8, wherein the said toy building block consists of a magnet, wherein the magnet used is a barium ferrite treated rubber magnetised layer.
11. The toy building block as claimed in claim 8, wherein the said toy building block has a magnet of thickness 0.5 to 0.6 mm.
12. The toy building block as claimed in claim 8 wherein, the thickness of the toy building block is in the range of 15 to 60 mm.
13. The toy building block as claimed in claim 8, wherein the said toy building block is a three dimensional block comprising of several shapes with a single or pair based interlocking mechanism in multitude of ways for plurality of the interconnected blocks to form various vibrant designs and structures.
14. A process for preparing the toy building colour and magentic block comprising:
a. Ginning and Separating gossypium hirsutum cotton to obtain its fiber;
b. Grinding and Separating pine wood to obtain fibers;
c. Cooking, Cleaning, Washing of the fibers in alkaline solution;
d. Refining and dyeing the fibers;
e. Placing the obtained colour fibers in mesh arrangement;
f. Treating the arrangement with polyvinyl acetate and pressing them under hot press;
g. Bonding two or numerous layers of the said substrate;
h. Moulding the numerous interlinked layers of the substrate to obtain the desired shape;
i. Slicing and pasting the magnet material vertically or horizontally inside the layers of the shaped block and sealing it with an adhesive paper sheet;
j. Drying the shaped block and cutting to its set size to obtain the toy building block.
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION
TOY BUILDING COTTON PAPER BLOCK AND PROCESS OF PREPARING THE
SAME
2. APPLICANT
a) UNIK INDUSTRIES
b) An Indian Company
c) 2/4, Gautam Chemical Compound, I.B Patel Road, Goregaon East, Mumbai- 400
063, Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in
which it is to be performed.
1
5 FIELD OF INVENTION
[001] The present invention relates to a cotton paper substrate for manufacturing a toy
building block with interlocking properties. More particularly, the present
invention relates to a toy building block comprising numerous layers of the cotton
paper substrate incorporating dye material or magnet material which can be used
10 as toy building colour block or toy building magnetic block respectively along
with a process for preparation of the said substrate and toy building block.
BACKGROUND OF INVENTION
[002] Toy building block can spark creativity and imagination in a multitude of ways in
15 order to help the child’s brain expand and get them into an opportunity of
nurturing their creativity and developing a niche thought process. The present
invention of the toy building block gives kids another avenue to explore science,
technology, engineering, art and mathematics. The toy building block provides a
cognitive touch in kids and creates curiosity in them to explore more with it, in
20 varieties of ways in form of designs and structures formed through the plurality
of the toy building blocks achieved via interconnection. The toy building blocks
can also help in refining child’s motor skill which require them to grab, paint,
push, pull, turn, or otherwise use their hands and body to make it perform
something which becomes instrumental in a child’s growth. Toy building parts
25 are usually in sets for various theme based arrangements for child’s play, which
in turn makes them overwhelmed with a variety of new ideas and different ways
of exploring and achieving it with the toy building blocks.
[003] Conventionally the toy building block is made from plastic called the acrylonitrile,
butadiene, styrene (ABS) which is derived from crude oil and natural gas and do
30 not contain any traces of paper pulp, or plant fiber or cotton; making it a liability
on the environment as it increases plastic pollution and harmfully impacts the
sustainability of the several natural resources along with the emissions of toxic
fumes of carbon dioxide arising from its raw materials used in the production of
the toy building block. The commercially available toy building block requires
35 massive energy in its production and has high inhalation toxic effects. Also the
raw material consumption is large, requiring a lot of heat to further process it.
2
Hence, the existing plastic toy building blocks and their 5 manufacturing process
and usage are not environmental friendly but also a big health issue for production
workers, end consumers and the nature.
[004] Considering the safety hazard issue the existing plastic toy building block are
troublesome and inconvenient.
10 [005] The toy building blocks have been made from a variety of materials including
plastics, wood, corrugated paperboard and have met with the commercial
acceptance as well but refinements are been sought to enhance ecological balance,
easier usage, novel, mass producible and economically friendly to boost creative
and mental growth of children with an enduring essence of endless imagination.
15 [006] US9364767B2 discloses a child building block having a collapsible structure
formed of a flat sheet that is bent into a block shape. The said patent discloses that
the toy building block is a flat planar sheet that is folded into a hollow block shape.
[007] US8756894B2 discloses foldable construction blocks made by folding sheet and
the said patent discloses about a system of using corrugated board and folding it
20 in ways to form the structure also comprising of a corrugated plastic sheet.
[008] US5662508A discloses a toy building block that is constructed in form of a
paperboard carton or box. It is made by folding the corrugated paperboard. The
said patent discloses the ways of folding the paperboard to form a toy building
block with a hollow tube like formed inside the toy building block.
25 [009] However, each of these blocks have a problem and the available paper sheet toy
building block is not a solid and rigid toy building block. They are folded in
various ways to form a toy building block. It is extremely inconvenient from a
physical usage point of view as the kids need to keep folding sheets in order to
form toy blocks. Improper folding lines can result in a mess for kids to form toy
30 blocks and eventually end up tearing those blocks. They are very light weight,
lack strength and are wobbly. They are hollow from within with a very small antibreaking
force thereby making the interconnection of the whole toy building block
weak and easily breakable even for the connection in plurality of these toy
building blocks respectively. Therefore, there is a need to develop a cotton paper
3
substrate for the toy building block that will overcome 5 the drawbacks of the
conventional toy building blocks.
OBJECT OF THE INVENTION:
[010] The main objective of the present invention is to a cotton paper substrate with
specific properties for making a toy block without making use of any folding
10 techniques, which can be used as toy building colour block or toy building
magnetic block.
[011] Another objective of the present invention is to provide a toy building block
comprising numerous layers of the cotton paper substrate comprising fibre
cellulose material incorporating magnet or dye for its use as toy building magnetic
15 block or toy building colour block.
[012] Yet another objective of the present invention is to a simple, economical and
industry viable process for preparation of the said cotton paper substrate and novel
toy building block to be used as toy building colour block or toy building magnetic
block.
20 [013] Other objects and advantages of the present invention will become apparent from
the following description taken in connection with the accompanying drawing.
SUMMARY OF THE INVENTION
[014] In an aspect of the present invention, the present invention provides a cotton paper
substrate comprising fiber cellulose of the gossypium hirsutum cotton, pine wood
25 pulp and at least one dyeing agent or magnet.
[015] In an aspect of the present invention, the present invention provides a toy building
block comprising numerous layers of the said paper substrate incorporating dye
or suitable magnet.
[016] In another aspect, the present invention provides a process for preparation of the
30 said cotton paper substrate.
[017] In yet another aspect, the present invention provides a process for preparation of
the toy building block comprising numerous layer of the said cotton paper
substrate.
4
[018] In yet another aspect, the present invention provides a 5 process for preparation of
numerous layered toy building colour block.
[019] In yet another aspect, the present invention provides a process for preparation of
numerous layered toy building magnet block.
[020] Unless otherwise defined, all the technical and scientific terms used herein have
10 the same meaning as understood by one of the ordinary skill in the art to which
the invention pertains. In case of any conflict, the present document, including
definitions will control.
BRIEF DESCRIPTION OF THE DRAWINGS
[021] FIG 1. illustrates a perspective view of the numerous layered toy building cotton
15 paper block with a front interlocking projection protruding through atleast one of
its external sides in the direction of perpendicular with respect to its plane, also
having a three-dimensional (3-D) orientation defined, to allow plurality of the
blocks.
[022] FIG 2. illustrates a perspective view of the toy building cotton paper block with
20 an exact cavity size of the interlock of the FIG 1, in order to allow vertical and/or
horizontal stacking of the blocks in a three-dimensional orientation in multitude
of ways.
[023] FIG 3. illustrates a perspective view of the toy block, and it can also have magnetic
attachment for vertical stalking of the blocks with a horizontal interlocking
25 through the groves. The dotted lines show the position of the magnets placed in
the upper and lower center of the block.
[024] FIG 4. illustrates a front view of the toy building cotton paper block with an
inverted “U” shaped protruding and interlocking cavity for vertical ways of
interlocked stacking and furthermore can also use magnetic columns for
30 horizontal interlocking, with varying positions of the interlocking cavity on its
outer surfaces. The dotted lines show the position of the magnets placed.
[025] FIG 5. illustrates a perspective view of the toy block with a different shape for
vibrant design and structure making having a position for interlocking cavity or
for placement of magnetic material, denoted by the dotted lines.
5
[026] FIG 6. illustrates a perspective view of the non-hollow c 5 ylindrical toy block.
[027] FIG 7. illustrates a perspective view from the top displacing a toy building block
in form of a trapezoid with a cavity at the bottom surface for interconnection and
an interlocking groove on its top surface for various design making.
[028] FIG 8. illustrates a perspective view from the left side of the corner showing a toy
10 building block in shape of a triangle having its side edge with grooves for
interlocking with other blocks.
DESCRIPTION OF THE INVENTION
[029] For the purpose of the following description, it is important to note that the
terminology used in the invention is for the purpose of describing particular
15 embodiments of the invention only, and is not at any point intended to limit the
scope of the invention in any manner. It is to be understood that the invention may
assume various alternative variations and step sequences, except where expressly
specified to the contrary.
[030] Furthermore, the invention is not limited to various embodiments given in the
20 specifications. It must be noted that, as used in this specification and the appended
claims, the singular forms “a,”” an,”” the” include plural referents unless the
content directs otherwise. The term “preferred” refer to the embodiments that have
certain benefits under certain circumstances. However, other embodiments can
also be preferred under the same or other circumstances. Therefore, repetition of
25 one of more preferred embodiments doesn’t not imply that other embodiment are
not useful and is not intended to exclude the other embodiments from the scope
of this invention. As used herein, the terms “comprising,” “including,” “having,”
“containing” to be understood as open-ended that is to mean including but not
limited to.
30 [031] Moreover, unless otherwise indicated, all numbers expressing, for example
quantities of ingredients used in the specification are to be understood as being
modified in all instances by the term “about”, with all the percentages given in
this specification and appended claims referring to percentages by weight of the
total composition.
6
[032] In an aspect the present invention provides a cotton paper 5 substrate comprising
fiber cellulose material having 40 to 50 % by weight of the fiber cellulose of
gossypium hirsutum cotton, 30 to 40% by weight of the fiber cellulose of pine
wood pulp, 20 to 25% tracheid cells, 2 to 4 % by weight of polyvinyl acetate.
[033] In an embodiment substrate further comprising atleast one dyeing agent or
10 magnet.
[034] In another aspect the present invention provides a cotton paper substrate
comprising fiber cellulose material having 40 to 50 % by weight of the fiber
cellulose of gossypium hirsutum cotton, 30 to 40% by weight of the fiber cellulose
of pine wood pulp, 20 to 25% tracheid cells, 2 to 4 % by weight of polyvinyl
15 acetate;
[035] 1 to 2 % by weight of starch and;
[036] 1 to 2% by weight of starch and atleast one dyeing agent or magnet.
[037] In an embodiment the fiber cellulose material is prepared from the gossypim
hirusutum cotton along with the fiber cellulose material from the pine wood pulp.
20 [038] In an embodiment the average length of these fibers is 9-10mm.
[039] In an embodiment the cotton paper substrate is having a binding polymer in the
range of 2 to 4 by weight%; pH content in the range of 7 to 7.5 by weight%;
moisture content in the range of 6 to 8 by weight% and sizing material in the range
of 1 to 2 by weight%
25 [040] In an embodiment the cellulose fibers of the substrate are stained with dye.
[041] In another embodiment the dye used is selected from natural dyes like the food
and plant pigments or synthetic dyes. The natural colours of marigold, saffron,
Caramel, cocoa, blueberries, raspberries, spinach, carrots and furthermore
authorised synthetic dye like Allure Red E 129 , Tartrazine E 102, Sunset yellow
30 E 110, Indigo carmine E 132 can also be used.
[042] In an embodiment the magnet used is a barium ferrite based rubber magnetised
layer having only one side magnetised with the north-south polarity, while the
other non-magnetized side glued along the said substrate.
7
[043] In another embodiment the thickness of the 5 magnet used is 0.5-0.6 mm.
[044] In an embodiment the present invention provides a numerous assorted layered toy
building cotton paper block with the substrate being prepared used as toy building
colour block or toy building magnetic block.
[045] In an embodiment the toy building block can be constructed to be a multi coloured
10 block, with fibers dyed using various vibrant colour shades and preparing the said
substrate to eventually make the toy building block.
[046] In an aspect the present invention a toy building cotton paper block comprising
two or numerous layers of sheet of cellulose fibers from the gossypium hirsutum
cotton having 40-50 % of fiber and that of the fiber cellulose material of pine
15 wood pulp having 30-40% of fiber, along with 2-4% of the polyvinyl acetate and
atleast either dyeing agent or magnet or both. Wherein the said sheets are bonded
using starch based glue to give strength and durability to the toy building block
with atleast one selected from the dyeing agent or magnet for its extended use.
[047] In an embodiment the toy building block comprises numerous layered thick sheet
20 cut in varying shape and bonded to each other where the upper and bottom layer
is generally optically white shade paper which can be either coated with colorant
or kept blank for kids to even paint the toy building blocks, with the middle layer
being the fiber paper to provide strength and absorbency control and not let the
toy building block get weak and wobbly.
25 [048] In another embodiment the cotton paper sheet for making the toy building block
is a fiber assorted and combined multilayer thick sheet. The outer layers of the
sheet can be coated with dye or kept blank, which could also allow kids to use
their imagination and paint the toy building blocks as they like.
[049] In an embodiment the toy building block comprises magnet in an amount of 3 to
30 5% by weight.
[050] In an embodiment the toy building blocks can be of varying shapes and vibrant
colours, including rectangular, square, trapezoid, cuboid, triangular, cylindrical
with non-hallow structure having various interlocking ways for interconnection.
8
[051] In an embodiment the toy building cotton paper block is 5 a single; durable; strong
block having high inter-fiber bonding with modular type connectors for stable and
rigid inter-connectivity for plurality of the toy building blocks. The toy building
block in accordance with the present invention is made from fiber cellulose cotton
paper substrate. It also eliminates the troublesome folding and bending of the prior
10 art toy building blocks and provides meaningful insights of three dimensional
connectivity through the present invention of the toy building cotton paper blocks.
[052] In an aspect the present invention provides a process for preparing the cotton paper
substrate containing:
I. Ginning and Separating gossypium hirsutum cotton to obtain its fiber;
15 II. Grinding and Separating pine wood to obtain fibers;
III. Cooking, Cleaning, Washing of the fibers in alkaline solution;
IV. Refining the fibers;
V. Optionally dyeing and drying the fibers;
VI. Placing the obtained fibers in mesh arrangement;
20 VII. Treating the interlinked arrangement with polyvinyl acetate and pressing them
under hot press;
VIII. Drying to form the required substrate.
[053] The alkaline solution used for fibers comprises of sodium hydroxide as an active
alkali, hydrogen peroxide, ethylene diamine tetraacetic acid and optionally using
25 titanium dioxide for added inter-fiber strength.
[054] Further, the process of manufacturing the present invention of the numerous
layered toy building block is simple, economical and environment friendly over
the conventional plastic toy building blocks. The toy building blocks of the
present invention are light, strong, rigid, durable, and easy to play and/or paint
30 and/or carry, along with a high inter-fiber bonding of its said substrate.
[055] In an aspect, the present invention provides a process for making the toy building
block comprising:
9
I. Preparing the 5 cotton paper substrate,
II. Bonding two or numerous layers of the said substrate;
III. Moulding the numerous interlinked layers of the substrate to obtain the
desired shape;
IV. Drying the shaped block and cutting to its set size to obtain the toy building
10 block.
[056] In an embodiment the toy building cotton paper block is having thickness in the
range between 15-60 mm.
[057] Alternatively, in another embodiment, the cotton paper substrate is made from the
waste cotton and cotton rags recovered and obtained from the textile factory and
15 also using the recycled and waste paper, made from the pine wood pulp, which is
prominently used in the pulp and paper industry in form of packaging product
materials. The waste wood material and the cotton waste is processed through
grinding, ginning and segregated into fibers; the fibers are then washed in an
alkaline solution using sodium hydroxide and hydrogen peroxide to remove the
20 impurities; the combination of the fibers are placed in mesh arrangements and
treated using polyvinyl acetate, which are then pressed and dried to form the
required substrate.
[058] In an embodiment the substrate used is recyclable and eco-friendly.
[059] In another embodiment the present invention provides a process for preparing the
25 toy building colour block comprising:
I. Ginning and Separating gossypium hirsutum cotton to obtain its fiber;
II. Grinding and Separating pine wood to obtain fibers;
III. Cooking, Cleaning, Washing of the fibers in alkaline solution;
IV. Refining the fibers;
30 V. Dyeing the fibers using the dye or colorants.
VI. Placing the obtained coloured fibers in mesh arrangement;
10
VII. Treating the interlinked arrangement with polyvinyl 5 acetate and pressing them
under hot press;
VIII. Drying to form the required substrate;
IX. Bonding and fusing two or numerous layers of the said substrate;
X. Moulding the layered substrate to obtain the desired shape;
10 XI. Drying the shaped block and cutting to its set size to obtain the toy building
block.
[060] In another embodiment the cotton paper substrate is treated with either dyeing
agent to prepare toy building colour block or using a magnet material to prepare
toy building magnetic block.
15 [061] In another embodiment the present invention provides a process for preparing the
toy building magnetic block comprising:
I. Ginning and Separating gossypium hirsutum cotton to obtain its fiber;
II. Grinding and Separating pine wood to obtain fibers;
III. Cooking, Cleaning, Washing of the fibers in alkaline solution;
20 IV. Refining the fibers;
V. Placing the obtained coloured fibers in mesh arrangement;
VI. Treating the arrangement with polyvinyl acetate and pressing them under hot
press;
VII. Drying to form the required substrate;
25 VIII. Bonding two or numerous layers of the said substrate;
IX. Moulding the multi layers of the substrate to obtain the desired shape;
X. Slicing and pasting the magnet vertically or horizontally inside the layers of the
shaped block and sealing it with an adhesive paper sheet.
XI. Drying the shaped block and cutting to its set size to obtain the toy building
30 block.
11
[062] The toy building block is strong, rigid, durable, stiff 5 having high inter-fiber
bonding for kids to play and enjoy building inter-connectable structures with also
an option to paint the toy building blocks. It is economical; mass producible and
ensuring as a novel playing toy.
[063] The advantages of the present invention includes:
10 1. It is a strong, rigid, durable toy building block which doesn’t need any folding
techniques to be done for its use.
2. It is made from natural source of fiber and is made to have high inter-fiber
strength.
3. The toy building block can also be kept blank, the kids can paint their toy building
15 blocks as per own choice.
4. These toy building blocks come in variants having coloured and/or magnetic
blocks versions.
5. The manufacturing process is industry feasible, simple and can be processed under
ambient temperature conditions for mass production.
20 6. The said toy building block can be recycled and is also biodegradable thereby
reducing pressure on the environment as compared to the existing plastic toy
blocks.
7. These toy building block have a three dimensional orientation type connectivity
for plurality of the blocks for various design and structural formations.
25 8. The thickness of the toy building blocks of the present invention is in the range of
15-60 mm, making it very flexible for the grip of kids to hold and play with it.
9. These toy building blocks are novel in one of the ways to accelerate sensory
movements and creativity among the kids.