U.S. patent application number 11/799006 was filed with the patent office on 2007-08-30 for systems and methods for building an interlocking decorative house.
Invention is credited to Debra A. Kolz.
Application Number | 20070202219 11/799006 |
Document ID | / |
Family ID | 32717919 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070202219 |
Kind Code |
A1 |
Kolz; Debra A. |
August 30, 2007 |
Systems and methods for building an interlocking decorative
house
Abstract
A special tabbed pattern is integrated into a series of forms.
The forms may be cookie cutters adapted to cut baked dough or other
material set to desired density to provide a series of panels
corresponding to the cutters. Alternatively, the forms may be
molds, e.g, adapted to receive melted chocolate which is allowed to
cool and set to form a series of panels corresponding to the molds.
The panels are adapted to be joined together to form a decorative
structure. The tabs are sized and positioned to provide a dovetail
joint along each edge of the structure. The protruding tabs or ends
are of a slightly smaller dimension than the notches that they fit
inside of to provide a secure fit. This self-interlocking design
allows each individual piece of the structure to be fitted
together, one at a time, while maintaining an acceptable degree of
stability throughout the assembly process.
Inventors: |
Kolz; Debra A.; (Grafton,
WI) |
Correspondence
Address: |
Patricia A. Limbach;RYAN KROMHOLZ & MANION, S.C.
Post Office Box 26618
Milwaukee
WI
53226-0618
US
|
Family ID: |
32717919 |
Appl. No.: |
11/799006 |
Filed: |
April 30, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10750700 |
Jan 2, 2004 |
7210920 |
|
|
11799006 |
Apr 30, 2007 |
|
|
|
60437708 |
Jan 2, 2003 |
|
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|
Current U.S.
Class: |
426/104 |
Current CPC
Class: |
A21C 15/04 20130101;
A21C 11/106 20130101; A21C 3/021 20130101 |
Class at
Publication: |
426/104 |
International
Class: |
A23L 1/48 20060101
A23L001/48 |
Claims
1. A kit for creating a decorative structure comprising: a pair of
end panels, each end panel having a bottom surface, a pair of
opposed side surfaces each having a tab and a notch, and a pair of
inclined top surfaces each having a tab and a notch, a pair of side
panels, each side panel having a top surface, a bottom surface, and
a pair of opposed side surfaces, each side surface having a tab and
a notch, and a pair of roof panels for the house, each roof panel
having a top surface, a bottom surface, and a pair of opposed side
surfaces, each side surface having a tab and a notch, the end
panels, roof panels, and side panels interlocking to form the
structure.
2. A kit as in claim 1, further comprising instructions for
use.
3. A kit as in claim 1 wherein at least one of the end panels, side
panels, or roof panels comprises an edible material.
4. A kit as in claim 1 wherein at least one of the end panels, side
panels, or roof panels comprises a non-edible material.
5. A kit as in claim 3 wherein said edible material comprises a
cookie material.
6. A kit as in claim 1, further comprising a decorating
material.
7. A kit as in claim 6 wherein at least a portion of said
decorating material further comprises an edible material.
8. A kit as in claim 6 wherein at least a portion of said
decorating material comprises a non-edible material.
9. A kit for creating a decorative structure comprising: a
plurality of panels, the panels providing a series of tabs and
notches adapted to interlock the panels, and a decorating
material.
10. A kit as in claim 9 wherein at least one of the panels
comprises an edible material.
11. A kit as in claim 9 wherein at least one of the panels
comprises a non-edible material.
12. A kit as in claim 9, further comprising instructions for
use.
13. A kit as in claim 9 wherein the panels are adapted to interlock
to form a three-dimensional structure.
14. A kit as in claim 9 wherein at least a portion of said
decorative material comprises an edible material.
15. A kit as in claim 9 wherein at least a portion of said
decorative material comprises a non-edible material.
16. A kit for creating a decorative structure comprising a
plurality of edible panels, the panels providing a series of tabs
and notches adapted to interlock the panels.
17. A kit as in claim 16, further comprising instructions for
use.
18. A kit as in claim 16, further comprising a decorating
material.
19. A kit as in claim 16 wherein the panels are adapted to
interlock to form a three-dimensional structure.
20. A kit as in claim 18 wherein at least a portion of said
decorative material comprises an edible material.
21. A kit as in claim 16 wherein the edible panels further comprise
a cookie material.
Description
RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S.
application Ser. No. 10/750,700 filed 2 Jan. 2004 and entitled
"Interlocking Assembly System and Related Methods for a Decorative
House" which claims the benefit of provisional Application Ser. No.
60/437,708, filed Jan. 2, 2003, and entitled "Interlocking Assembly
System and Related Methods for a Decorative House."
FIELD OF THE INVENTION
[0002] The invention relates to the construction of decorative
houses.
BACKGROUND OF THE INVENTION
[0003] Decorative structures, particularly edible decorative
structures, such as gingerbread houses, are well-known. Such
structures are routinely made and displayed, especially for
specially occasions, such as birthdays or Christmas. Children, in
particular, enjoy participating in the decorating process.
Historically, assembly of a gingerbread house has been an awkward
and time-consuming task. Icing, in particular icings having an egg
white base, such as royal icing, have traditionally been used to
bond the individual panels of a structure together. The icing
method is difficult to implement due to the amount of drying time
required. Gingerbread house builders typically need a great degree
of patience and may rely upon some sort of makeshift propping
system to help stabilize the structure while the icing is setting.
The icing assembly method can therefore be a frustrating experience
for both adults and children. The frustration often limits
enjoyment of the finished structure and may even prevent completion
of the structure.
[0004] The need therefore remains for systems and methods for
creating a decorative structure that are time and cost-efficient.
The need further remains for systems and methods that permit ease
of assembly while maintaining an acceptable degree of stability
throughout the assembly process.
SUMMARY OF THE INVENTION
[0005] A special tabbed pattern is integrated into each joining
panel of a decorative structure. The tabs are sized and positioned
to provide a dovetail joint along each edge of the structure. The
protruding tabs or ends are of a slightly smaller dimension than
the notches that they fit inside of, thus providing a secure fit.
This self-interlocking design allows each individual piece of the
structure to be fitted together, one at a time, while maintaining
an acceptable degree of stability throughout the assembly
process.
[0006] One aspect of the invention provides a kit for creating a
decorative structure. The kit provides a plurality of pre-made or
pre-cut panels and a decorating material. The panels provide a
series of tabs and notches that are adapted to interlock the
panels. In one embodiment, the kit comprises a pair of end panels,
a pair of side panels, a pair of roof panels, and a decorating
material. Each end panel has a bottom surface, a pair of opposed
side surfaces each having a tab and a notch, and a pair of inclined
top surfaces each having a tab and a notch. Each side panel has a
top surface, a bottom surface, and a. pair of opposed side
surfaces, each side surface having a tab and a notch. Each roof
panel has a top surface, a bottom surface, and a pair of opposed
side surfaces, each side surface having a tab and a notch.
[0007] Another aspect of the invention provides a kit for creating
a decorative structure. The kit comprises a plurality of edible
panels. The panels provide a series of tabs and notches adapted to
interlock the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view illustrating the cutting of a
cookie panel from a tabbed cookie cutter.
[0009] FIG. 2 is a perspective view illustrating the interlocking
of a pair of tabbed cookie panels having the same
configuration.
[0010] FIG. 3 is a perspective view illustrating the interlocking
of a pair of tabbed cookie panels having different
configurations.
[0011] FIG. 4 is a perspective view of a make it from scratch
baking kit for making a decorative structure.
[0012] FIG. 5 is a top view illustrating the use of a pair of dough
gauges to roll a ball of dough on a cookie sheet to a uniform
desired thickness.
[0013] FIG. 6 is a perspective view of an alternative embodiment in
which the cookie sheet includes raised edges.
[0014] FIG. 7 is a top view illustrating the layout on cookie
sheets of a series of panels required to assemble a decorative
structure.
[0015] FIG. 8 is a perspective view illustrating the use of a lined
pan to mold melted chocolate to a desired length, width and
height.
[0016] FIG. 9 is a perspective view illustrating the use of a
series of molds to mold melted chocolate into desired panels.
[0017] FIG. 10 is a schematic illustrating the dimensions of a side
panel cutter in a representative embodiment.
[0018] FIG. 11 is a schematic illustrating the dimensions of a roof
panel cutter in a representative embodiment.
[0019] FIG. 12 is a schematic illustrating the dimensions of an end
panel cutter in a representative embodiment.
[0020] FIG. 13 is a perspective view illustrating the interlocking
of a side panel with an end panel.
[0021] FIG. 14 is a perspective view illustrating the interlocking
of a second side panel with the end panel.
[0022] FIG. 15 is a perspective view illustrating the interlocking
of a second end panel with the side panels.
[0023] FIG. 16 is a perspective view illustrating the interlocking
of the roof panel with the end panels to rest the roof panel on a
side panel.
[0024] FIG. 17 is a perspective view illustrating the interlocking
of a second roof panel with the end panels to rest the second roof
panel on the second side panel to complete assembly of the
structure.
[0025] FIG. 18 is a perspective view of a ready to assemble
decorating kit for making a decorative structure.
[0026] FIG. 19 is a top view of an alternative embodiment of a side
panel cutter in which the cutter includes a window cutting
surface.
[0027] FIG. 20 is a top view of an alternative embodiment of an end
panel cutter in which the cutter includes a door cutting
surface.
[0028] FIG. 21 is a perspective view of an alternative embodiment
of a decorative structure in which the side panel includes a window
and the end panel includes a door.
[0029] FIG. 22 is a perspective view of an alternative embodiment
in which an interior panel is placed within the structure.
[0030] FIG. 23 is a schematic illustrating the dimensions of a side
panel cutter in an alternative embodiment.
[0031] FIG. 24 is a schematic illustrating the dimensions of a roof
panel cutter in an alternative embodiment.
[0032] FIG. 25 is a schematic illustrating the dimensions of an end
panel cutter in an alternative embodiment.
[0033] FIG. 26 is a perspective of a decorative structure
constructed from panels formed by the cutters of FIGS. 23-25.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Although the disclosure hereof is detailed and exact to
enable those skilled in the art to practice the invention, the
physical embodiments herein disclosed merely exemplify the
invention that may be embodied in other specific structure. While
the preferred embodiment has been described, the details may be
changed without departing from the invention, which is defined by
the claims.
[0035] I. Interlocking Panels
[0036] FIG. 1 illustrates a cookie cutter 10 providing a series of
protruding ends or tabs 12 defining a series of notches 14. The
cutter 10 is adapted to be pressed into a material or substance 16
to cut a panel 18 having a corresponding series of notches 20 and
tabs 22. The material 16 may be baked cookie or various other types
of edible materials, such as shortbread or solid chocolate. It is
to be understood that the cutter 10 can be manufactured with a
peripheral or outer cutting edge 24 suitable to accommodate varying
densities of material 16, e.g., semi-set chocolate, baked cookie or
dog biscuit. This eliminates the need to manufacture separate sets
of cutters 10 for different materials 16, resulting in further cost
savings. In one alternative embodiment, the panel 18 is made of dog
biscuit material or other materials 16 edible by an animal. In some
cases, it may be desirable for the panel 18 to be suitable for
long-term display as a decoration. Therefore, it is contemplated
that the panel 18 may be made from non-perishable and/or non-edible
materials 16, e.g., clay or salt dough (which may be hardened or
finished by drying or baking operation). It is further contemplated
that the panels 18 may be formed of the same or of different
materials 16. For example, a first panel 18 may be formed of
gingerbread and a second panel 18 may be formed of shortbread.
[0037] The cutter 10 may be made of any suitable food safe
material, e.g., 18 g stainless steel. Desirably, the cutter 10
includes a tab or knob 26 for easy grasping and manipulation.
[0038] The tab 22 of a first panel 18 is sized and configured to
interlock with a complementary notch 20 on a second panel 18 and
the notch 20 of the first panel 18 is sized and configured to
interlock with a complementary tab 22 on the second panel 18 to
form a series of interlocking panels 18.
[0039] In the embodiment shown in FIG. 2, a pair of panels 18 are
formed from the same cutter 10 and have the same configuration,
e.g., rectangular, with the panels 18 being joined in a planar
pattern as shown in FIG. 2. In another embodiment, a first panel
18A is formed by a first cutter 10A. A second panel 18B is formed
from a second cutter 10B having a different configuration than the
first cutter 10A, e.g., the first cutter 10A has a rectangular
configuration and the second cutter 10B has a square configuration,
with the panels 18A and 18B being joined in a planar pattern as
shown in FIG. 3.
[0040] The tabs or ends 22 are desirably of a slightly smaller
dimension than the notches 20 that they fit inside of the notches
20, thus providing a secure fit, similar to a jigsaw puzzle. The
cutter 10 may be provided in virtually any regular or irregular
geometric size and shape. It is apparent that a series of cutters
10 of different configurations may be provided to form a series of
corresponding panels 18 to create virtually any pattern.
[0041] II. Creation of a Decorative Structure Using
A Series of Interlocking Panels
[0042] The interlocking assembly system may also be used in
creating a variety of non-planar or three-dimensional structures.
The system provides a custom engineered, self-supportive design
that enables a person to easily join together the individual
elements of the decorative structure. The system is particularly
well suited for constructing an edible structure, e.g., a
gingerbread house. Therefore, the system and methods will be
described in accordance with the construction of an edible
structure.
[0043] The interlocking assembly method may be offered to the
consumer in the form of a "make it from scratch" kit or a
"prepared, ready to assemble" kit, and may be integrated into any
type of food-cutting or food-shaping apparatus that is used to
create a food structure, particularly, a cookie house. A cutting or
shaping apparatus that utilizes the interlocking assembly method
may be provided in virtually any regular or irregular geometric
size and shape so that the components of the structure, when
assembled, may resemble any type of structure or building, such as
a house.
[0044] FIG. 4 shows a "make it from scratch" baking kit 28 for
constructing a decorative structure, e.g., a house 30 (see also
FIG. 17). The food structure 30 is not necessarily limited to a
specific flavor or substance such as gingerbread cookie, but may
include various other types of edible materials, such as shortbread
or solid chocolate. In one alternative embodiment, the structure 30
is made of dog biscuit material or other materials edible by an
animal. In some cases, it may be desirable for the structure 30 to
be suitable for long-term display as a decoration. Therefore, it is
contemplated that the structure 30 may be made from non-perishable
and/or non-edible materials, e.g., clay or salt dough (which may be
hardened or finished by baking operation).
[0045] The kit 28 provides an end panel cookie cutter 32, a roof
panel cookie cutter 34, and a side panel cookie cutter 36. Cutters
32/34/36 act as a form for creating, respectively, a pair of end
panels 38, a pair of roof panels 40, and a pair of side panels 42,
as will be described in detail later (see also FIG. 6). Panels
38/40//42 may variously sized to produce a structure 30 of an
infinite variety of dimensions. The kit 28 may also include mix 44,
a pair of gauges 46, decorating material 48, and instructions for
use 50. If desired, the kit 28 may also include a variety of
additional items to further facilitate the creation, storage and/or
transport of the structure 30. Such items include, but are not
limited to, bakery parchment paper to provide a working surface, a
plate or platform (e.g., cardboard) for displaying and/or
transporting the assembled structure 30, a bag (e.g., plastic) for
wrapping the finished decorated structure 30 for storage or
transport, and a box, which may take the shape of a house
complementary to the shape of the finished structure 30, or other
storage or gift container sized to receive the assembled structure
30 (not shown). The kit 28 greatly streamlines the entire process
of creating a gingerbread house 30 from scratch. The planning step
is therefore minimal and cost effective, as the kit 28 supplies a
design to follow, and includes most of the baking and decorating
ingredients necessary for execution, with the exception of a few
fresh items.
[0046] In some cases, the cook or baker may wish to provide his or
her own recipe. Desirably, a specially formulated recipe is
provided, with at least some of the ingredients supplied as part of
the kit 28 in the form of mix 44. For example, in one embodiment,
the mix 44 provides pre-measured dry ingredients, e.g., flour,
sugar, and spices. The baker need only add a few fresh ingredients,
much like a dry cake mix from the supermarket. Fresh ingredients
may include, but are not limited to, eggs, molasses, and butter.
The custom-blended, pre-packaged, dry cookie mix 44 eliminates the
need to have the required dry ingredients on hand, as well as the
need to measure and blend each ingredient accordingly. The cookie
mix 44 may be provided in any desired type or flavor, e.g.,
gingerbread, chocolate, shortbread. To maximize cost efficiency,
the mix 44 may also be sold or provided separately from kit 28 to
permit reuse of other kit 28 components.
[0047] With reference now to FIG. 5, the baker adds the fresh
ingredients to the mix and mixes to form a batter or dough 52. The
recipe is formulated to provide dough 52 of proper texture and
consistency at room temperature. Therefore, the
specially-formulated recipe results in additional time-savings
because there is no chilling required. The recipe is desirably also
formulated to yield a quantity of baked dough 52 greater than what
is required to create the featured structure 30, thereby providing
extra baked material 16 as additional treats to sample and eat. The
specially formulated recipe also provides panels 38/40/42 of the
stability necessary to successfully join the individual panels
38/40/42 securely together, in addition to supporting the weight of
the icing and confectionary products when fully decorated.
[0048] As seen in FIG. 5, the dough 52 is placed between the gauges
46 and partially flatted by hand. A conventional rolling pin 54 or
other suitable device is then rolled simultaneously across the
dough 52 and the gauges 40 to roll or flatten the dough 52 to a
desired thickness that essentially corresponds to the height of the
gauges 40 and those dimensions of the cookie cutters 32/24/36 that
are integral to properly being able to interlock the individual
panels 38/40/42 together.
[0049] It is to be understood that the gauges 40 and cutters
32/24/36 are specifically engineered to work together to ensure
that the required thickness is established and evenly maintained
from panel 32/24/36 to panel 32/24/36, therefore guaranteeing that
the baked, cutout panels 32/24/36 fit properly together. The dough
52 may be flattened and rolled directly on a greased cookie sheet
56. The cookie sheet 56 becomes the work surface, rather than a
bread board or counter, making clean-up easier and quicker.
[0050] The gauges 46 enable the baker to roll the dough 52 a
uniform desired thickness. The desired thickness may vary by the
material being used. For example, in a representative embodiment,
the dough 52 is gingerbread dough rolled approximately 3/8inch
thick.
[0051] The gauges 46 may be variously constructed. The size and
configuration of the gauges 46 may be customized, e.g., for use
with different types of dough 52 and for specific baking
operations. In the illustrated embodiment, the gauges 46 take the
form of a pair of elongated rectangular rods. The gauges 46 may be
made of any suitable food safe material, e.g., wood, metal,
plastic. In a preferred embodiment, the gauges 46 are made of a
food safe acrylic material that is washable to permit reuse. The
gauges 46 are desirably built to a specified height to consistently
roll the dough 52 to a uniform desired thickness. In a
representative embodiment, each gauge 46 is 12 inches long, 3/16to
4/16inch high and 1/2inch wide.
[0052] In an alternative embodiment, seen in FIG. 6, cookie sheet
56 includes raised, depth control edges 58 along long sides 60 of
the cookie sheet 56. Edges 58 are similar to gauges 46, but are
formed integral with the cookie sheet 56 to enable the baker to
roll the dough 52 to a uniform desired thickness. The depth of the
edges 58 corresponds to the desired thickness, which may vary by
the material being used. If desired, edges 58 may also be included
along short sides 62 of the cookie sheet 56 (not shown). In one
embodiment, cookie sheet 56 with raised edges 58 is provided to the
consumer as part of kit 28. In this embodiment, gauges 46 could be
omitted from the kit 28.
[0053] The rolled dough 52 is baked as rough, oversized shapes at
the temperature and time period instructed. The specified time and
temperature will vary according to the type of dough 52 being used,
as well as the type and size of cookie sheet 56 being used. The
dough 52 is set or hardened to a cookie by the baking
operation.
[0054] With reference to FIG. 7, the baked cookie 58 is allowed to
slightly cool and set. End panel cutter 32 is pressed into the
slightly cooled cookie 58 at two different locations to form a pair
of end panels 38. Similarly, a pair of roof panels 40 are formed
from roof panel cutter 34 and a pair of side panels 42 are formed
from side panel cutter 36. Cutting the panels 38/40/42 from the
baked cookie 58 rather than unbaked dough 52 (which undergoes
expansion during the baking process) assures that the panels
38/40/42 will be of a consistent size, thereby assuring a proper
interlocking fit between the assembled panels 38/40/42. Leftover
cookie 58 after cutting of the panels 38/40/42 can be eaten and
enjoyed.
[0055] In one alternative embodiment, seen in FIG. 8, solid
chocolate 66 may be used to create a structure 30. In this example,
the chocolate 66 (which has desirably been previously melted) is
poured into a buttered or lined baking pan 68 to first mold the
chocolate 66 into a length, width and height suitable for the size
of structure 30 that is being created. The pan 68 may be formed of
any suitable food safe material, e.g., stainless steel, to permit
easy cleaning and reuse. Once the chocolate 66 has semi-set to the
correct hardness, the cutters 32/34/36 are pressed into the
chocolate 66 to form the panels 38/40/42 of the structure 30. The
pan 68 may include a fill line 70 to assure that the chocolate 66
is poured to uniform, desired depth. In this embodiment, kit 28
would include pan 68, chocolate 66, decorating materials 48,
cutters 32/34/36, and instructions 50. Mix 44 and gauges 46 could
be omitted from the kit 28.
[0056] Alternatively, instead of pan 68, melted chocolate 66 may be
poured into a series of chocolate molds, eliminating the need for
cutters 32/34/36. As seen in FIG. 9, melted chocolate 66 is poured
into each of an end panel mold 71A, a roof panel mold 71B, and a
side panel mold 71C and allowed to set. The molds 71A/71B/71C
function as an alternative form to cutters 32/32/36 to form panels
38/40/42 respectively. The molds 71A/71B/71C include a series of
notches 74A and tabs 76A similar to notches and tabs 74 and 76 of
cutters 32/34/36. Desirably, the molds 71A/71B/71C include a fill
line 70 to assure uniform depth. The panels 38/40/42 are then
removed from the respective molds 71A/71B/71C. The molds
71A/71B/71C may be formed of any suitable material, e.g., food safe
plastic, to permit easy cleaning and reuse. In this embodiment, kit
28 would include molds 71A/71B/71C, chocolate 66, decorating
materials 48, and instructions 50. It may be desirable to provide a
pair each of end panel molds 71A, roof panel molds 71B, and side
panel molds 71C so that the necessary panels (two end panels 38,
two roof panels 40, and two side panels 42) may be made
concurrently, resulting in additional time savings.
[0057] Each cutter 32/34/36 may include a knob 26, e.g., 1/4inch
diameter, centered on cutter 32/34/36, for easy grasping as
previously described. Desirably, the outer edges of the cutters
32/34/36 include a bend down of approximately 90.degree. to form a
peripheral cutting surface 72 (see FIG. 8). In a representative
embodiment, the cutters 32/34/36 are approximately 3/4inch in depth
to readily accommodate a variety of baked cookie 58 depths. Each
cutter 32/34/36 desirably provides a series of complementary
notches 74 and protruding ends or tabs 76 along at least one outer
edge of the cutter 32/34/36 (see FIG. 4). The corresponding panels
38/40/42 provide a corresponding series of perimeter notches 78 and
tabs 80 which interlock to secure the individual panels 38/40/42
together to create the structure 30 (see FIG. 16). The tabs 80 are
of a slightly smaller dimension than the notches 78 that they fit
inside of, thus providing a secure fit. The size, number, and
placement of tabs 76/80 and notches 74/78 may be varied,
particularly as to size of the panels 38/40/42, to assure stability
of the assembled structure 30. In the illustrated embodiment, tabs
76 and notches 74 are of a generally rectangular configuration. It
is contemplated, however, that tabs 76 and notches 74 may be
variously configured, e.g., rounded 5 or other curvilinear
configuration (not shown). The self-supporting, interlocking
arrangement does not require an icing or other "glue" to act as an
adhesive.
[0058] FIGS. 10-12 illustrate inner dimensions A-N for the cutters
32/34/36 (or molds 71A/71B/71C) in a 10 representative embodiment
as follows: TABLE-US-00001 A 1/2 inch B 5/8 inch C 1 inch D 1 1/32
inches E 1 1/16 inches F 1 13/32 inches G 1 7/16 inches H 11/2
inches I 1 17/32 inches J 31/2 inches K 5 inches L 5 11/16 inches M
6 inches N 85/8 inches
[0059] When dimensioned according to the above representative
embodiment, four standard size 14 in..times.16 in. cookie sheets 56
can accommodate the necessary panels (two end panels 38, two roof
panels 40, and two side panels 42) in the arrangement illustrated
in FIG. 7.
[0060] However, most standard ovens will not readily accommodate
four cookie sheets 56 at one time and therefore at least 20 two
baking operations may be required. Alternatively, one professional
size 13 1/2in..times.17 in. cookie sheet 56 can accommodate one end
panel 38, one roof panel 40, and one side panel 42. In this
arrangement, only two cookie sheets 56 are required. The two cookie
sheets 56 are readily accommodated in most standard ovens, cutting
baking time in half and reducing cleanup.
[0061] This above-described sequence of baking steps, in
conjunction with the use of furnished ingredients and prepping
equipment will provide easy and successful creation and assembly.
The interlocking assembly method provides the means for a baker to
easily create and assemble an edible structure 30 that they have
made from scratch. The tabbed pattern allows each individual panel
38/40/42 of the structure 30 to be fitted together, one at a time,
while maintaining an acceptable degree of stability throughout the
assembly process.
[0062] In assembling the structure 30, a side panel 42 is
interlocked with an end panel 38, as shown in FIG. 12. The end
panel 38 includes a bottom surface 82, a pair of side surfaces 84,
and a pair of inclined top surfaces 86. The side panel 42 is
generally rectangular-shaped and includes a top surface 88, a
bottom surface 90, and a pair of side surfaces 92. As FIG. 13
shows, each side surface 92 of side panel 42 carries a tab 80 sized
and configured to interlock with a complementary notch 78 on a side
surface 84 of an end panel 38 to interlock the side and end panels
42 and 38.
[0063] In a similar manner, the second side panel 42 is then
interlocked with the end panel 38, as shown in FIG. 14. The
interlocking design provides sufficient stability to the
semi-assembled structure without the aid of icing, hands, or props.
As seen in FIG. 15, a second end panel 38 is interlocked with the
pair of side panels 42.
[0064] As FIG. 16 shows, the four base panels (two side panels 42
and two end panels 38) easily accept and support a roof panel 40.
The roof panel 40 is generally square-shaped, having a top surface
94, a bottom surface 96, and a pair of side surfaces 98. Each side
surface 98 carries a series of tabs 80 and notches 78 that
interlock with complementary notches 78 and tabs 80 on inclined top
surfaces 86 of end panels 38 to interlock roof and end panels 40
and 38. The bottom surface 96 of the roof panel 40 is sized and
configured to abut the top surface 88 of the adjacent side panel
42. In a similar manner, the second side panel 40 is then
interlocked with the end panels 38 to complete assembly of the
structure 30, as shown in FIG. 17. The assembled structure 30
remains completely self-supportive.
[0065] The assembled structure 30 is then decorated as desired.
Preferably, suggested designs are included in the instructions 50
for the consumer's reference. The decorating step can be an
expensive one as several types of packaged confectionary products
are typically purchased to achieve greater detail and uniqueness in
the finished product. Therefore, the kit 28 desirably includes the
decorating accessories 48, thereby greatly simplifying the process
as well as making it more cost-effective. The decorating
accessories may include a variety of confectionary products, such
as icing (e.g., microwavable chocolate), nuts, coconut, cookies,
etc. The icing serves to further bond the panels 38/40/42 together,
thereby providing additional stability to the finished structure
30.
[0066] Non-bakers or those short on time may wish to place greater
emphasis upon the decorating process. Children, in particular, will
derive a great entertainment value from the assembly and decorating
process alone. Therefore, a series of pre-baked and pre-cut panels
38/40/42, which may be cookie, solid chocolate or some other type
of edible or non-edible substance as previously noted, may be
provided to the consumer in the form of a "prepared, ready to
assemble" decorating kit 28A, shown in FIG. 18. The panels 38/40/42
may be pre-cut by a series of cutters 32/34/36. Alternatively, the
panels 38/40/42 may be cut by any other suitable method providing
sufficiently precise results, e.g., a water jet. By eliminating the
baking process, the pre-cut panels 38/40/42 allow the consumer to
focus on the assembly and decorating process. The kit 28A
preferably includes decorating materials 48 and instructions 50 for
use, as previously described. The pre-cut panels 38/40/42 are
assembled with ease as previously described to form the structure
30. The structure 30 is then decorated as desired. By eliminating
the need to purchase a variety of individual decorating materials
48, the decorating kit 28A greatly streamlines the entire
decorating process.
[0067] Some users may desire that the structure 30 provide
additional aesthetic elements. For example, in an alternative
embodiment illustrated in FIGS. 19-21, end panel cutter 32 includes
a door cutting surface 100 for cutting a door 102 in end panel 38.
Similarly, side panel cutter 36 includes a window cutting surface
104 for cutting a window 106 in side panel 36. Cutting surfaces 100
and 104 may be tack welded to cutters 32 and 36 respectively. It is
apparent that the number and placement of doors 102 and windows 106
may be varied to produce a structure 30 of the desired
architecture. Kit 28 preferably incorporates a series of cutters
32/34/36 having the desired elements.
[0068] In the illustrated embodiment, the assembled structure 30
comprises first and second end panels 38, first and second roof
panels 40, and first and second side panels 42. It is contemplated
that the structure 30 may be varied by providing a greater or
lesser number of top, end, or side panels 38/40/42 to create a
structure 30 of virtually any configuration. In one alternative
embodiment, a floor panel can be provided (not shown).
[0069] As seen in FIG. 22, in cases where the interior of the house
30 is visible (e.g., by addition of a door 102), it may be
desirable to provide an interior panel 108, formed with an interior
panel cutter (not shown), or a series of interior panels 108
extending horizontally and/or vertically within the interior of the
structure 30 to divide the interior of the structure 30, e.g., into
10 rooms. To support the interior panels 108 within the structure,
the interior panels 108 may include tabs 110 for interlocking with
complementary slots 112 provided in one or more of panels
38/40/42.
[0070] FIGS. 23-25 illustrate inner dimensions A'-N' for an end
panel cutter 132, a roof panel cutter 134, and a side panel cutter
136 in an alternative embodiment as follows: TABLE-US-00002 A'
1.406 inches B' .938 inch C' .375 inch D' .781 inch E' 5.880 inches
F' 1.178 inches G' 1.673 inches H' .895 inch I' 3.25 inches J' 4.0
inches K' .750 inch L' .766 inch M' .968 inch N' 2.50 inches O'
3.75 inches P' 1.391 inches
[0071] When dimensioned according to this representative
embodiment, the necessary panels (two end panels 138, two roof
panels 140, and two side panels 142) can be accommodated on a
single standard 14 in..times.16 in. cookie sheet 56.
[0072] Cutters 132/134/136 have a tabbed arrangement similar to the
embodiment illustrated in FIGS. 10-12. The tabbed arrangement
allows the panels 132/134/136 to be assembled in an interlocking
manner similar to the embodiment of FIGS. 13-17 to form a structure
130, as seen in FIG. 26.
[0073] The foregoing is considered as illustrative only of the
principles of the invention. Furthermore, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described. While the preferred
embodiment has been described, the details may be changed without
departing from the invention, which is defined by the claims.
* * * * *