U.S. patent application number 12/917709 was filed with the patent office on 2011-11-17 for cardboard play structure.
This patent application is currently assigned to Build A Dream Playhouses, LLC. Invention is credited to Sam Cahill, Andy Carcioppolo, Michael Welsh.
Application Number | 20110281495 12/917709 |
Document ID | / |
Family ID | 44912176 |
Filed Date | 2011-11-17 |
United States Patent
Application |
20110281495 |
Kind Code |
A1 |
Welsh; Michael ; et
al. |
November 17, 2011 |
CARDBOARD PLAY STRUCTURE
Abstract
A foldable cardboard play structure is provided that comprises
at least a first and second foldable cardboard panel, wherein at
least the first foldable panel includes one or more first tabs,
each of the one or more first tabs corresponding to a slot located
on at least the second foldable panel. The slots are adapted to
receive the corresponding first tab and at least one of the first
and second foldable panels include one or more edge portions having
at least one fold line and a second tab thereon. The edge portions
are configured to wrap around exposed rough edges of the other of
the first and second foldable panel.
Inventors: |
Welsh; Michael; (Gates
Mills, OH) ; Carcioppolo; Andy; (Chesterland, OH)
; Cahill; Sam; (Cleveland, OH) |
Assignee: |
Build A Dream Playhouses,
LLC
|
Family ID: |
44912176 |
Appl. No.: |
12/917709 |
Filed: |
November 2, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61334310 |
May 13, 2010 |
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Current U.S.
Class: |
446/478 |
Current CPC
Class: |
A63H 17/00 20130101;
A63H 33/16 20130101 |
Class at
Publication: |
446/478 |
International
Class: |
A63H 3/52 20060101
A63H003/52 |
Claims
1. A foldable cardboard play structure comprising: at least a first
and second foldable cardboard panel, wherein at least said first
foldable panel includes one or more first tabs, each of said one or
more first tabs corresponding to a slot located on at least said
second foldable panel, said slots adapted to receive said
corresponding first tabs, and wherein at least one of said first
and second foldable panels include one or more edge portions having
at least one fold line and a second tab thereon, said edge portions
being configured to wrap around exposed rough edges of the other of
said first and second foldable panel.
2. The play structure according to claim 1, wherein said cardboard
is corrugated.
3. The play structure according to claim 1, wherein said fold lines
of said edge portions further include slits adapted to receive said
second tabs.
4. The play structure according to claim 1, wherein a portion of
said first tabs is wider than said slots.
5. The play structure according to claim 4, wherein said portion is
configured to fold to be received by said corresponding slot.
6. The play structure according to claim 5, wherein said portion is
configured to butterfly open after insertion into a slot, locking
the first tab in position.
7. The play structure according to claim 1, wherein said cardboard
panels include an inner surface and an outer surface, said outer
surface is customizable.
8. The play structure according to claim 1, wherein said structure
forms one of a vehicle, jet plane, and concession stand.
9. The play structure according to claim 8, wherein said vehicle
structure includes one or more of an entry door capable of handedly
rotating open and closed, a window, a storage space, a side mirror,
and a dashboard.
10. The play structure according to claim 8, wherein said jet
includes one or more of a wing panel, a backrest, and carrying
handles.
11. The play structure according to claim 8, wherein said
concession stand includes one or more of an awning, a sign, a menu,
a cabinet, and a countertop.
12. A method for assembling a cardboard play structure comprising:
providing at least two cardboard panels including a corresponding
number of tabs and complementary slots; securing at least said
first cardboard panel to said second cardboard panel by inserting
one or more first tabs on one of said first or second panel into
one or more corresponding slots on the other of said first and
second panel; and eliminating exposed edges from said one or more
cardboard panels by wrapping an edge portion of one of the first
and second cardboard panels around the other of said first and
second cardboard panels and inserting a second tab located on the
edge portion to insert into a corresponding slit provided on a fold
line of the same cardboard panel.
13. The method according to claim 2, further including
disassembling said cardboard play structure by removing any
inserted tabs and flattening the structure for at least one of
travel and storage.
14. The method according to claim 2, wherein a portion of said
first tabs is wider than said slots.
15. The method according to claim 4, further including folding the
wider portion of the first tabs prior to inserting said first tabs
into said slots and unfolding said wider portion after the first
tabs are fully inserted into the slots.
16. A kit for assembling a cardboard play structure for pretend
play, said kit comprising: at least two cardboard panels capable of
being assembled into a play structure; one or more accessory
pieces; and decorating materials for customizing said play
structure, wherein said cardboard panels include one of a plurality
of tabs and a plurality of corresponding slots, wherein said slots
are adapted to receive said corresponding tabs to join said one or
more cardboard panels.
17. The kit according to claim 14, wherein said cardboard is
corrugated cardboard.
18. The kit according to claim 14, wherein at least one of said
cardboard panels further includes edge portions having tabs and
corresponding slits thereon, said edge portions configured to wrap
around corresponding portions on another cardboard panel and insert
said tab into said corresponding slit.
19. The play structure according to claim 1, wherein a portion of
said tabs is wider than said slots.
20. The play structure according to claim 4, wherein a said portion
is configured to butterfly open after insertion into a slot,
locking the tab in position.
Description
FIELD OF INVENTION
[0001] The present disclosure relates to play structures, and more
particularly to play structures made out of cardboard. It finds
particular application in conjunction with corrugated cardboard
foldable play structures, and will be described with particular
reference thereto. However, it is to be appreciated that the
present exemplary embodiments herein are also amenable to other
like applications.
BACKGROUND
[0002] Play structures for childhood pretend play have been used
for many years and have taken the form of anything from a tree
house to club house to a lemonade stand. Children love the
limitless bounds their imaginations can explore in pretend play.
Pretend play structures may be as simple as draping a sheet over
two chairs or as intricate as wooden or plastic play houses that
resemble castles, log cabins, princess quarters, etc.
[0003] Foldable cardboard is commonly used to create playhouses and
other toy structures for children. Cardboard play structures
provide an eco-friendly adventure for children and allow children
to use their imaginations to create their own unique play space.
Typically, these structures are constructed out of corrugated
cardboard or other paperboard material and include outlines for
cutting and folding the structure into the desired shape. The
structure is then assembled and glued into final form. Such
structures are often designed to create play spaces, such as
houses, castles, vehicles, rockets, and the like.
[0004] Foldable structures such as those commonly known in the art
generally require complicated and intricate assembly, such that one
person cannot assembly the structure alone. Additionally, such
cardboard play structures include exposed, sharp edges that pose a
threat to a child's safety. For example, US 2005/0260919 describes
a method for assembling a play house that provides tabs to mate
with slots on adjoining sections to secure the two sections
together. However, the tabs are provided on edges that will remain
exposed even after the tabs are inserted into the slots.
Additionally, the tabs are simply inserted into the slots without
any further locking or support means. As such, there exists a need
for safe, sturdy, easy to assembly play structures. Accordingly, it
is an object herein to provide foldable, pop-up play structures
with improved safety features and ease of assembly.
SUMMARY OF THE DISCLOSURE
[0005] In accordance with one aspect of the present disclosure, a
foldable cardboard play structure is provided. The foldable
cardboard play structure comprises at least a first and second
foldable cardboard panel, wherein at least the first foldable panel
includes one or more first tabs, each of the one or more first tabs
corresponding to a slot located on at least the second foldable
panel. The slots are adapted to receive the corresponding first tab
and at least one of the first and second foldable panels include
one or more edge portions having at least one fold line and a
second tab thereon. The edge portions are configured to wrap around
exposed rough edges of the other of the first and second foldable
panel.
[0006] In accordance with another aspect of the present disclosure,
a method for assembling a cardboard play structure is provided. The
method includes providing at least two cardboard panels including a
corresponding number of tabs and complementary slots, securing at
least the first cardboard panel to the second cardboard panel by
inserting one or more tabs on one of the first or second panel into
one or more corresponding slots on the other of the first and
second panel, and eliminating exposed edges from the one or more
cardboard panels by wrapping a portion of one of the first and
second cardboard panels around the other of the first and second
cardboard panels and inserting a tab located on the portion to
insert into a corresponding slit provided in a fold line of the
same cardboard panel.
[0007] In accordance with yet another aspect of the present
disclosure, a kit for assembling a cardboard play structure for
pretend play is provided. The kit comprises at least two cardboard
panels capable of being assembled into a play structure, one or
more accessory pieces, and decorating materials for customizing the
play structure. The cardboard panels include one of a plurality of
tabs and a plurality of corresponding slots. The slots are adapted
to receive the corresponding tabs to join the one or more cardboard
panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a pre-assembled view of play structure vehicle
panels according to one aspect of the present disclosure;
[0009] FIG. 2 illustrates two side panels of the play structure
vehicle in accordance with one exemplary embodiment;
[0010] FIG. 3(a)-(c) illustrate an assembly step for an exemplary
play structure vehicle according to one aspect of the present
disclosure;
[0011] FIG. 4 illustrates an incomplete attachment of a front panel
of the play structure vehicle according to one aspect of the
present disclosure;
[0012] FIG. 5(a)-(b) illustrate another assembly step for an
exemplary play structure vehicle;
[0013] FIG. 6(a)-(c) illustrate another assembly step for an
exemplary play structure vehicle to provide smooth, safe edges;
[0014] FIG. 7(a)-(b) illustrate a rear perspective view of an
exemplary play structure vehicle during assembly;
[0015] FIG. 8(a)-(h) illustrate an assembly step for an exemplary
play structure vehicle;
[0016] FIG. 9(a)-(b) illustrate an assembly step for an exemplary
play structure vehicle according to one aspect of the present
disclosure;
[0017] FIG. 10 illustrates a process for attaching side view
mirrors to an exemplary play structure vehicle;
[0018] FIG. 11(a)-(e) illustrate various perspective views of a
fully assembled exemplary play structure vehicle in accordance with
one aspect of the present disclosure;
[0019] FIG. 12 illustrates pre-assembled play structure jet panels
according to one aspect of the present disclosure;
[0020] FIG. 13 illustrates one aspect of the assembly of an
exemplary play structure jet;
[0021] FIG. 14 illustrates another aspect of the assembly of an
exemplary play structure jet;
[0022] FIG. 15 illustrates another aspect of the assembly of an
exemplary play structure jet;
[0023] FIG. 16(a)-(d) illustrates another aspect of the assembly of
an exemplary play structure jet;
[0024] FIG. 17(a)-(c) are various perspective views of a fully
assembled exemplary play structure jet in accordance with one
aspect of the present disclosure;
[0025] FIG. 18 illustrates pre-assembled play structure concession
stand panels according to one aspect of the present disclosure;
[0026] FIG. 19 illustrates one assembly step for an exemplary play
structure concession stand;
[0027] FIG. 20 illustrates another assembly step for an exemplary
play structure concession stand;
[0028] FIG. 21 illustrates another assembly step for an exemplary
play structure concession stand;
[0029] FIG. 22 illustrates another assembly step for an exemplary
play structure concession stand;
[0030] FIG. 23(a)-(b) illustrate yet another assembly step for an
exemplary play structure concession stand; and
[0031] FIG. 24(a)-(b) are various perspective views of a fully
assembled exemplary play structure jet in accordance with one
aspect of the present disclosure.
DETAILED DESCRIPTION
[0032] Cardboard playhouses are provided that utilize improved
construction and method of assembly, making the structures easier
to assemble, safer, and more durable. The cardboard playhouses
according to the subject application incorporate the banker's box
method of assembly, which allows for simplified, single person
construction and also increases the playhouse safety. The banker's
box method involves wrapping a piece of cardboard around itself or
another piece of cardboard to cover any exposed corrugated edges.
This strengthens the rigidity of the structure, while also
protecting users from potential injury from the sharp edges.
Additionally, the playhouse assembly according to the present
invention utilizes otherwise useless scraps created by die lines by
implementing various features. This assembly does not require glue
or other permanent adhesive, so it is easily flattened for storage
and travel. Both the packaging and product comprise 100% recycled
materials.
[0033] The cardboard playhouses according to one embodiment may
comprise double-walled corrugated cardboard, such as B flute, B
Flute 200 LB/WT, ECT-32 B, and other such materials. The product
assembly utilizes a series of tabs and slots that allow the
playhouses to be "stitched" together on the edges of adjoining
sections of cardboard. A user may insert the tab of one section
into the corresponding slot of another section, resulting in a
"stitch." The tabs are preferably wider at the end to be inserted
into a slot, such that once a tab is inserted into a slot, the tab
itself butterflies open to lock the "stitch" in place. This
"stitching" technique, coupled with the banker's box technique
increases the structural rigidity and product safety. This assembly
method is simplified to enable assembly by a single user.
[0034] The following exemplary embodiments comprise corrugated
cardboard structures intended for pretend play. The cardboard
preferably comprises one "outer" surface, that may be white,
colored, or include graphics, either printed or otherwise, for
decorating purposes similar to a coloring book. The embodiments
herein are described such that the outer surface is white and the
inner surface is the typical brown kraft cardboard for exemplary
purposes only; however, other configurations are contemplated
herein. The play structures may be sold with decorating kits,
including decorating materials such as stickers, markers, crayons,
pencils, scissors, ribbons, paper, and/or other accessories. The
decorating materials/accessories may also be provided
separately.
[0035] Referring now to the figures and more particularly to FIGS.
1-6, an exemplary foldable corrugated cardboard car play structure
is provided. FIG. 1 illustrates the pre-assembled car of this
particular embodiment that consists of seven pieces, although more
or less pieces may be provided if desired. A right side panel (A)
and left side panel (B) is provided, such that the left side panel
(B) may serve as the driver's side and the right side panel (B) may
serve as the passenger side, although an opposite configuration may
be implemented for right-hand drive vehicles. Each side panel
comprises a front side 111 and rear side 113 window, with an entry
door 115 directly below the front side window 111, such that the
top of the entry door 115 comprises the bottom edge of the window.
The entry doors 115 are detached from the side panels (A),(B) along
the rear side and bottom, such that the doors are can be hingedly
rotated open and closed and may include a handle 125 for opening
and closing the door. Other pieces of the car assembly may include
a front panel (C), including a grill and a hood and right and left
side view mirrors (D). Rear panel (E) may include a rear bumper and
trunk lid with a handle, and a roof panel (F), that may include a
windshield 117, dashboard 121, sunroof 123 and a rear hatch with a
rear window 119 in the center portion of the hatch.
[0036] The car assembly may come in variety of sizes, for all ages
of users, one particular embodiment has packaged dimensions of
about 54''L.times.29.5''H.times.1.75''W and unpackaged dimensions
of 53.5''L.times.27''H.times.34.5''W. While in this particular
embodiment the car assembly takes the form of a
hatchback/wagon/SUV/hybrid, the car is not limited to this
structure and may alternatively take the form of convertible,
van/minivan, safari vehicle, jeep/4.times.4, race car, indy car,
formula one car, drag car, go kart, dune buggy, school bus, bus,
police car, fire truck, ambulance, taxi, pizza delivery car, ice
cream truck, truck, pick-up truck, limo, antique car, muscle car,
mystery machine, golf cart, police truck, armored vehicle,
train/locomotive/caboose, tractor, bull dozer, crane, semi-truck,
plow truck, ATV, tank, military vehicle, moon rover, space vehicle,
submarine, motorcycle/side car, carriage, covered wagon,
stagecoach, hot air balloon, blimp, boat, jet ski, car bed, and the
like. For instance, in the case of an ice cream truck, the rear
panel (E) may additionally include rear entry door, such as double
doors, different shaped parts, and different/additional
accessories.
[0037] FIGS. 2-11 illustratively exemplify the assembly of the
corrugated cardboard car play structure according to one aspect of
the disclosure. Prior to the first step, the designated labeled
cardboard tabs and creases should be folded to prepare for
assembly. The assembly of structures according to other designs
contemplated herein may include additional and/or different steps,
and/or may exclude certain steps, to accommodate the various
features of each design.
[0038] With reference to FIG. 2, side panels (A) and (B) each
include foldable bottom portions about 2-3 inches from the bottom
that run parallel to the bottom edge of the side panel. Each side
panel may be folded at the crease lines such that there is a flat
panel resting on the ground to the interior play area of the car,
to provide improved support and stability.
[0039] The front panel (C) of the car may then be attached to side
panels (A) and (B). Standing at the front of the car, the front
panel is attached to the side panels (A) and (B) beginning at the
bottom (tab 1) and working up towards the top of the front panel
(C) (FIG. 3(a). Each tab 1-3 on either side of the front panel (C)
is inserted into the corresponding slots on the side panels. As
best illustrated in FIGS. 3(b) and (c), one a tab is inserted into
a slot, the tab should be folded over from the interior and pushed
back through a corresponding slit provided in a fold line of front
panel (C) that is parallel to the tab, securing the tab in place.
FIG. 4 illustrates an incomplete attachment of the front panel (C),
wherein tabs 1 and 2 of the left side are fully inserted and
secured and tabs 1 and 2 of the right side panel (A) are inserted
and secured. Finally, left and right tabs 3 are inserted into the
corresponding tabs to button up the front panel. (See FIG. 3(b)).
Preferably, both the right and left tabs 1 are inserted prior to
inserting tab 2, etc.
[0040] FIGS. 5(a)-(b) illustrate the process of joining the rear
panel (E) of the car with the side panels (A),(B). As displayed in
FIG. 5(a), the rear panel (E) includes an end piece with two side
sections, each with one or more tabs corresponding to one or more
slots on each of the left (B) and the right (A) side panels. The
rear panel is attached to the side panels (A),(B) beginning at the
top (tab 1) of the side panels and working down towards the bottom.
Tab 1 is initially inserted into slot 1 of the left side panel (B).
After insertion, tab 1 is to be folded back against the side panel
from the interior and inserted into a corresponding slit provided
in a fold line parallel to the tab on the rear panel (E) to lock
the tab in place. This is to be repeated with tab 1 on the right
side. If there is more than one tab on each side of the rear panel,
both the left and right tab 1's should be inserted into the
corresponding slots and secured in the fold line slits prior to
moving on to subsequent tabs. FIG. 5(b) displays the rear panel (E)
fully attached to the side panels (B) and (A) with each tab
inserted into the corresponding slot and secured. The top side of
rear panel (E) further includes tabs 7 and 8, which should be left
folded out for later use.
[0041] FIGS. 6 (a),(b) illustrates one exemplary method of
attaching the roof panel (F) to the right (A) and left (B) side
panels. Tabs 9-16 of the roof panel (F) are wrapped around
corresponding support structures of the corresponding side panels.
From the interior of the car assembly, the tabs are tucked back
into corresponding slits provided on the fold lines of the roof
panel. The support structures of the side panels corresponding with
each of tabs 9-16 also make up the top and side edges of the front
side and rear side windows. Each tab 9-16 should be sequentially
secured to the side panels, such that the tabs wrap around each
correspondingly numbered support structure located on the side
panels and tab back to corresponding slits in the fold lines of
roof panel (F) to secure the roof panel to the car assembly, as
illustrated in FIG. 6(c). This banker's box folding method of
assembly eliminates the potential for exposing sharp edges by
ensuring all edges are smooth folds, and not rough end pieces. FIG.
6(b) illustrates the car assembly having the roof panel (F) and the
two side panels (A),(B) securely attached. The front section of the
roof panel is tucked under the hood.
[0042] As illustrated in FIG. 7(a), rear panel (E) further includes
tabs extending from the top edge of the rear panel (E) and two sets
of slots on either side of the trunk hatch 146. To form the rear
window 119, tabs 7 and 8 may be folded over the top edge of the
rear panel (E) and through corresponding upper slots 142 and back
through lower slots 144 as illustrated in FIG. 7(b). Tabs 7 and 8
are preferably shaped such that the tops of the tabs are wide than
the slots 142 and 144. To manage tabs 7 and 8 through slots 142 and
144, the tabs should be folded. Unfolding the tabs after they are
inserted through the slots ensures the tabs are locked in place.
The folding of tabs 7 and 8 over the bottom of the rear window 119
ensures that the rear window edge is not sharp and rough, but
rather smooth and rounded for user safety.
[0043] As illustrated in FIG. 8(a), the top side of the front panel
(C) includes left and right tabs 17, which are short tabs that may
be inserted into corresponding slots located on the dashboard 121.
Also shown in FIG. 8(a), the hood portion of the front panel
includes two sets of slots 141, a first and second right slot and a
first and second left slot. Right and left tabs 18 extending
downwardly from the dashboard 121 (FIG. 8(c)), are pulled through
the right and left first slots (FIG. 8(c)) in the hood portion and
woven through the second left and right slits. As with tabs 7 and 8
above, tabs 18 may be wider at the top than slots 141 (See FIG.
8(e)-(g). As such, tabs 18 should be folded prior to inserting into
the slots and should be unfolded once the tabs are in place,
securing the dashboard in the appropriate position while creating
only smooth, safe contours (FIG. 8(d)). As illustrated in FIG.
8(h), the bottom portion of the dashboard 121 folds under when tabs
18 are secured in place. A half-circle portion is cut out of the
bottom portion, such that as the bottom portion folds under the
dashboard, the half-circle remains in place, creating a steering
wheel-like portion 143. The dashboard 121 may include any variety
of components, such as multiple gauges positioned about the
dashboard, a radio, and a glove compartment that is designed to
open and close.
[0044] As illustrated in FIG. 9(a) and (b), window edges are formed
by folding tabs 20 and 21 towards the interior, such that the tabs
are inserted into corresponding slots according to the banker's box
method discussed above. Door flaps are then folded towards the
interior (FIG. 9(b) and then a tab is pushed through a
corresponding slot to create a handle on the exterior.
[0045] The side view mirrors (D) may then be attached to the car by
inserting tabs located on the mirrors into slots provided on the
side panels. (FIG. 10)).
[0046] The fully assembled form of the corrugated cardboard car is
assembled such that the car functions as an enclosed playhouse that
may be mobile or immobile. FIGS. 11(a)-(e) illustrate one
embodiment of the car assembly according to one aspect of the
present disclosure. FIG. 11(a) is a driver-side view of the car
with the driver-side door ajar. FIG. 11(b) illustrates a left
side-front view, highlighting the folding method's elimination of
rough and dangerous edges and instead provides smooth and rounded
edges ensuring improved strength and safety. FIG. 11(c) displays
the car from a right side-back view and FIG. 11(d) exemplifies a
rear view, highlighting the opening in the back panel acting as a
trunk hatch that users may use to load/unload the car. Finally,
FIG. 11(e) illustrates a top view of the car assembly according to
the present embodiment with an optional sunroof 123 located in the
top panel.
[0047] In another exemplary embodiment, a corrugated cardboard
structure is provided in the form of a jet plane. The jet plane may
come in many sizes, for all ages of users, one particular
embodiment has packaged dimensions of
54''.times.29.5''H.times.1.65''W and unpackaged dimensions of
53.5''L.times.27''H.times.34.5 and then we will For exemplary
purposes, this play structure will be described as a jet fighter
plane; however other designs are also contemplated including, but
not limited to a jet, plane, spaceship, rocket ship, rocket,
glider, speeder, submarine, formula race car, fighter jet,
bi-plane, military aircraft, cargo plane, passenger jet, powered
chute, blimp, zeppelin, kite, bomber, UFO, ultra light, hot air
balloon, space craft, space shuttle, hover craft, bob sled, soap
box derby car, downhill racer, dragster, roller coaster, speed
boat, row boat, jet ski, motorcycle, dirt bike, time machine,
fortune telling machine, pin ball machine, arcade machine, escape
pod, sleep pod, snowmobile, sled, hybrid, plane bed, and the
like.
[0048] FIG. 12 illustrates the pre-assembled, die cut outs of a jet
fighter plane according to one aspect of the present embodiment.
The plane includes a body panel (G), a right and left wing panel
(H), and a rear panel (I) including a backrest portion. Other
embodiments contemplated herein may include additional or
alternative assembly parts.
[0049] FIGS. 13-15 illustratively exemplify an assembly of the
corrugated cardboard jet fighter plane playhouse according to one
aspect of the present disclosure. Prior to the first step, the
pre-designated cardboard tabs and creases should be pre-folded for
ease of assembly. This particular embodiment is described with a
white outer surface and an inner surface of brown kraft cardboard;
however this description is for exemplary purposes only. Other
configurations and designs are contemplated herein. The assemblies
of structures according to other designs contemplated herein may
include additional and/or different steps, and/or may exclude
certain steps, to accommodate the various features of each
design.
[0050] To connect the nose of the jet, the sides of the body are
folded downwardly as illustrated in FIG. 13. Tabs 30 and 31 are
then inserted into corresponding slots 32 and 33 to secure the nose
in a tight formation. Tabs 30 and 31 have wide ends such that the
tabs should be folded prior to inserting into the slots. After the
tabs have been inserted, the folds can be released to lock the tabs
securely in place. After the nose is assembled, the body is
preferably prepared for the remaining assembly steps by pre-folding
each of the edges on the body panel (G) inwardly toward the middle
of the body panel (G). (See FIG. 14).
[0051] FIG. 15 illustrates the assembly of the backrest portion by
attaching the rear panel (I) to the jet assembly body panel (G).
The body panel is placed over the rear panel (I), such that the
rear panel extends lengthwise below the length of the body panel
(G) with the narrow portion towards the nose of the jet. Tabs 40-43
extending along the rear panel (I) are inserted into corresponding
slots 40-43 on the body panel (G). As with the tabs described
above, tabs 40-43 are to be folded to fit into slots 40-43, and are
then to be unfolded to secure in place. Inserting each of the tabs
into the corresponding slots forms a backrest portion in the middle
portion of the jet.
[0052] To attach the right and left wing panel (H) to the jet
assembly, the wing panels must first be folded together by
inserting tabs 44 and 45 through corresponding slots 46 and 47,
respectively, as illustrated in FIG. 16(a). FIG. 16(b) illustrates
one method of attaching the assembled wing panels (H) to the body
panel (G). Tabs 48-49 on the right wing panel and 50-51 on the left
wing panel are inserted into corresponding slots on the body panel
(G). Once the tabs are inserted into the slots, the tabs can be
unfolded from the interior of the jet assembly to secure the tabs
in place. If the tabs 43 on the rear panel (I) are not yet inserted
into the corresponding slots on the body panel (G), the tabs may be
inserted to close and secure the jet plane assembly body, as
illustrated in FIG. 16(c). The control panel may be assembled with
the jet plane as illustrated in FIG. 16(d), by folding the control
panel down from the nose portion of the body panel (G), such that a
tab (not shown) is inserted up through slot 56 and then back down
through slot 57, securing the control panel in place at the nose of
the jet plane assembly.
[0053] The fully assembled form of the exemplary corrugated
cardboard jet plane is displayed in FIGS. 17(a)-17(c). FIG. 17(a)
shows a left frontal side view of one aspect of the assembled jet
plane. FIG. 17(b) shows a rear view of the assembled plane. FIG.
17(c) shows a view of the interior of the plane, including the
control panel according to one exemplary embodiment. The jet plane
further includes handles that allow a user to pick up the jet while
standing inside the cockpit, assisting mobile play.
[0054] In accordance with another aspect of the present disclosure,
a corrugated cardboard structure is provided in the form of a
stand, and more particularly a concession stand. The concession
stand may come in many sizes, for all ages of users, one particular
embodiment has packaged dimensions of
24''L.times.30.5''H.times.2''W and unpackaged dimensions of
46''L.times.31.5''H.times.31.5''W. For exemplary purposes, this
play structure will be described as a concession stand; however
other designs are also contemplated including, but not limited to a
lemonade stand, pizza stand, kiosk, snack bar, wet bar, bar, street
vendor, vending machine, hotdog stand, gyro stand, bakery, drive
through window, ice cream stand, restaurant, tea party set,
produce/market stand, gas station/pump, advice stand, corner
playhouse, work desk, drawing table, furniture, deli, outdoor
grill, fold up kitchen/laundry room, patio, gazebo, lifeguard
station, vanity, school house, fold up book, and the like.
[0055] FIG. 18 illustrates the pre-assembled, die cut outs of the
concession stand according to the present embodiment. The stand
includes two side body panels (J), including drop down awnings with
sign insertion slots, outside reinforcement wrap-around columns 175
and a drop down counter support 173; two cabinet panels (K), two
countertops (L); an optional menu (M) and interchangeable signage
(N). Other embodiments contemplated herein may include alternative
and/or additional assembly parts.
[0056] FIGS. 19-22 exemplify the assembly of the corrugated
cardboard concession stand play structure according to one
exemplary embodiment. Prior to the first step, the pre-designated
cardboard tabs and creases should be pre-folded to necessary
prepare for assembly. This particular embodiment is described with
cardboard having a white outer surface and white inner surface;
however this description is for exemplary purposes only. Other
configurations and designs are contemplated herein. The assemblies
of play structures according to other designs may include
additional/different steps, to accommodate the various features of
each design.
[0057] In a first exemplary embodiment, the columns 175 of the side
body panels (J) are folded inwardly, such as to create support
columns (FIG. 19). To secure the columns in place, tabs 61-64 are
sequentially inserted into corresponding tabs 65-68 located on the
side body panels, respectively, as illustrated in FIG. 18. The tabs
preferably include a portion with a width greater than the width of
the slots, such that the tabs must be folded in order to enter the
slots and unfolded after insertion. The tabs are then unfolded
post-insertion to lock in place and secure the assembly. Tabs 71,
72, and 73 may then be inserted into corresponding slots on the
opposite side body panel to join the two side body panels (J) along
one edge. The side body panels (J) are preferably joined such that
the panels form a substantially right angle (90.degree.) with one
another. The tabs 71, 72, 73 preferably include a hook-like shape,
such that once the tabs are inserted into the slots, the tabs are
slid downwardly towards the base of the side body panel to lock
into place. This locking method is exemplified in FIG. 20.
[0058] FIG. 21 illustrates an exemplary method of assembling the
cabinet panels (K) with the stand side body panels (J). The cabinet
panels (K) may be prepared by folding the panels along lines x,
with the tabs 75-79 extending behind the main cabinet body (FIG.
21). Tabs 75-77 on each of the cabinet panels (K) may then be
inserted into corresponding slots on the side body panels, as
depicted in FIG. 22. The tabs 75-77 should be pushed through to the
outside of the slot and then back through to the inside by a
second, parallel slot. Since it is preferred that the tabs be of
the type that include a greater width at the end entering the slot,
the tabs should be unfolded after insertion through the second
slot, to lock the tab in place.
[0059] Referring back to FIG. 18, side body panels (J) include
counter portions 173 that can be folded downwardly to create a
generally 90.degree. angle with the panel (J). Folding down the
counter portions on each of the side body panels (J) creates a
window-like area through the center of the panels, as is shown in
FIG. 22. To secure the counter portions 173 in place, tabs 77 and
78, extending upwardly from the top side of each cabinet panel, are
inserted through corresponding slots in the counter portions. At
this point, the tabs should remain extended, and not folded over to
lay flat on the countertop. At least one, and preferably two,
additional countertops (L) are stacked on top of the counter
portions 173 and corresponding tabs 77 and 78. The tabs 77 and 78
are pushed through corresponding slots located on the countertops
(L) and then pushed back downwardly through a second slot located
on the countertop to create a smooth, flat, countertop surface.
[0060] In one exemplary embodiment, side body panels (J) further
include awning portions 180 comprising two foldable portions and
tabs 80 and 81. To assemble the awnings, it is preferred that the
awning portions 180 be hanging down from the top of the stand, as
shown in FIG. 18. The awning portions 180 may then be folded
upwardly, such that a portion of the awning comprising tabs 80 and
81 is folded over the top edge of the side body panel and the tabs
80,81 may be inserted into the corresponding tabs located on the
side body panels (J), as shown in FIG. 23(a). The tabs 80,81 may
further extend through slits provided in the fold line located on
the awning portions. One or more signs (N) and a menu may then be
inserted into the slot provided in the awning portions 180. (FIG.
23(b)).
[0061] One embodiment of a fully assembled stand, complete with an
awning and sign is illustrated in FIGS. 24(a)-(b). FIG. 24(a) shows
a front center view of the stand and FIG. 24(b) illustrates an
interior "worker" view of the stand.
[0062] The exemplary embodiment has been described with reference
to the preferred embodiments. Obviously, modifications and
alterations will occur to others upon reading and understanding the
preceding detailed description. It is intended that the exemplary
embodiment be construed as including all such modifications and
alterations insofar as they come within the scope of the appended
claims or the equivalents thereof.
* * * * *