U.S. patent application number 14/580618 was filed with the patent office on 2015-06-25 for pod toy.
The applicant listed for this patent is David Berglund. Invention is credited to David Berglund.
Application Number | 20150174504 14/580618 |
Document ID | / |
Family ID | 53398994 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150174504 |
Kind Code |
A1 |
Berglund; David |
June 25, 2015 |
POD TOY
Abstract
A pod toy may include a plurality of substantially similar
panels each having a wall portion and a roof portion, the plurality
of panels having at least one interlocking edge having alternating
notches and knuckles configured for engaging adjacent panels,
where, when assembled, the interlocking edge of a first panel
engages an interlocking edge of a second panel by aligning knuckles
of the first panel with knuckles of the second panel, and a
connecting pin configured for insertion into and through the
knuckles at the interlocking edges.
Inventors: |
Berglund; David;
(Minnetonka, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Berglund; David |
Minnetonka |
MN |
US |
|
|
Family ID: |
53398994 |
Appl. No.: |
14/580618 |
Filed: |
December 23, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61920224 |
Dec 23, 2013 |
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Current U.S.
Class: |
472/136 |
Current CPC
Class: |
A63H 33/42 20130101;
A63H 33/008 20130101 |
International
Class: |
A63H 33/42 20060101
A63H033/42 |
Claims
1. A pod toy comprising: a plurality of substantially similar
panels each having a wall portion and a roof portion, the plurality
of panels having at least one interlocking edge having alternating
notches and knuckles configured for engaging adjacent panels,
wherein, when assembled, the interlocking edge of a first panel
engages an interlocking edge of a second panel by aligning knuckles
of the first panel with knuckles of the second panel; and a
connecting pin configured for insertion into and through the
knuckles at the interlocking edges.
2. The pod toy of claim 1, wherein each panel of the plurality of
substantially similar panels is foldable from a single piece of
material.
3. The pod toy of claim 2, wherein the single piece of material is
substantially flat with no overlapping portions.
4. The pod toy of claim 1, wherein the plurality of substantially
similar panels differ due to surface openings and are substantially
identical along their respective interconnecting edges.
5. The pod toy of claim 1, wherein the wall portions of the
plurality of substantially similar panels form four walls.
6. The pod toy of claim 5, wherein the wall portions include a
gable shape.
7. The pod toy of claim 5, further comprising a pyramidal shaped
roof.
8. The pod toy of claim 7, wherein the pyramidal shaped roof is
rotated 45 degrees from the orientation of the four walls.
9. The pod toy of claim 7, further comprising a roof opening in the
center of the roof.
10. The pod toy of claim 1, wherein the plurality of substantially
similar panels comprise a sustainable material.
11. The pod toy of claim 10, wherein the sustainable material is
cardboard.
12. The pod toy of claim 11, wherein the connecting pin is a paper
tube.
13. The pod toy of claim 1, wherein the plurality of substantially
similar panels each define a wall having a bottom free edge, a left
interlocking edge, a right interlocking edge, an interlocking gable
edge, and a folded gable edge.
14. The pod toy of claim 13, wherein the left interlocking edge is
configured to interlock with an adjoining right edge of an adjacent
panel.
15. The pod toy of claim 14, wherein one of the substantially
similar panels includes a door opening and a door.
16. The pod toy of claim 15, wherein the door comprises an interior
handle configured for frictionally engaging a door jamb of the door
opening.
17. The pod toy of claim 16, wherein one of the plurality of
substantially similar panels includes a slot in a roof portion for
insertion of a connecting pin therethrough.
18. The pod toy of claim 1, wherein the knuckles have a
substantially square cross-section.
19. The pod toy of claim 1, wherein the knuckles have a
substantially parallelogram shaped cross section.
20. The pod toy of claim 1, wherein the roof portion can support a
child weighing 75 pounds.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 61/920,224 entitled Pod Toy, filed on Dec.
23, 2013, the content of which is hereby incorporated by reference
herein in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a pod for a child such as
a fort, hut, enclosure, or other space that can be occupied by a
child for play. More particularly, the present disclosure relates
to a sustainable design for a pod. Still more particularly, the
present disclosure relates to a structurally sturdy design for a
pod including a working door, windows, and a roof opening.
BACKGROUND OF THE INVENTION
[0003] The background description provided herein is for the
purpose of generally presenting the context of the disclosure. Work
of the presently named inventors, to the extent it is described in
this background section, as well as aspects of the description that
may not otherwise qualify as prior art at the time of filing, are
neither expressly nor impliedly admitted as prior art against the
present disclosure.
[0004] Creation of forts or other enclosures within a home for
children to play in has long since been a way to entertain. More
recently, manufacturers have begun creating cardboard play systems
in the form of castles, rockets, and the like. The play systems may
be white in color and may come with or be sold in conjunction with
or marketed with markers, crayons, or other writing or coloring
devices. The overall goal of these systems appears to be to sell
more markers or crayons while providing the children with a
temporary structure to play with. However, the cardboard play
systems are weak-walled and very unstable.
BRIEF SUMMARY OF THE INVENTION
[0005] The following presents a simplified summary of one or more
embodiments of the present disclosure in order to provide a basic
understanding of such embodiments. This summary is not an extensive
overview of all contemplated embodiments, and is intended to
neither identify key or critical elements of all embodiments, nor
delineate the scope of any or all embodiments.
[0006] In one or more embodiments, a pod toy may include a
plurality of substantially similar panels each having a wall
portion and a roof portion. The plurality of panels may have at
least one interlocking edge with alternating notches and knuckles
configured for engaging adjacent panels. When assembled, the
interlocking edge of a first panel may engage an interlocking edge
of a second panel by aligning knuckles of the first panel with
knuckles of the second panel. The toy may also include a connecting
pin configured for insertion into and through the knuckles at the
interlocking edges. In contrast to cardboard play systems currently
being provided, the present pod toy may be structurally stable with
a series of stiffened edges and corners making a pod toy that is
not only durable but is capable of supporting the weight of a
child. As such, the pod toy may function as a but or fort, for
example, but may also allow for climbing in, on, and around,
without collapse or general degradation of the toy.
[0007] While various embodiments are disclosed, still other
embodiments of the present disclosure will become apparent to those
skilled in the art from the following detailed description, which
shows and describes illustrative embodiments of the invention. As
will be realized, the various embodiments of the present disclosure
are capable of modifications in various obvious aspects, all
without departing from the spirit and scope of the present
disclosure. Accordingly, the drawings and detailed description are
to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter that is
regarded as forming the various embodiments of the present
disclosure, it is believed that the invention will be better
understood from the following description taken in conjunction with
the accompanying Figures, in which:
[0009] FIG. 1 is a front/right side perspective view of a pod toy,
according to one or more embodiments.
[0010] FIG. 2 is a rear/left side perspective view of the pod toy
of FIG. 1, according to one or more embodiments.
[0011] FIG. 3a is back side view of the pod toy of FIG. 1,
according to one or more embodiments.
[0012] FIG. 3b is a left side view of the pod toy of FIG. 1,
according to one or more embodiments.
[0013] FIG. 3c is a right side view of the pod toy of FIG. 1,
according to one or more embodiments.
[0014] FIG. 3d is a front side view of the pod toy of FIG. 1,
according to one or more embodiments.
[0015] FIG. 4 is a top view of the pod toy of FIG. 1, according to
one or more embodiments.
[0016] FIG. 5 is a bottom view of a pod toy similar to that of FIG.
1, but with the back and left sides interchanged, according to one
or more embodiments.
[0017] FIG. 6 is an exploded view of the pod toy of FIG. 5,
according to one or more embodiments.
[0018] FIG. 7 is an exploded view of the pod toy of FIG. 5 showing
the assembly of the rear wall and the left side wall, according to
one or more embodiments.
[0019] FIG. 8 is a cross-section view of a bottom edge of the walls
of the pod toy, according to one or more embodiments.
[0020] FIG. 9 is a cross-section view of a gable corner, according
to one or more embodiments.
[0021] FIG. 10 is a cross-section view of a side-adjoining or
vertical corner, according to one or more embodiments.
[0022] FIG. 11 is a cross-section view of a ridge, according to one
or more embodiments.
[0023] FIG. 12 is a cross-section view of a top opening edge,
according to one or more embodiments.
[0024] FIG. 13A is a cross-section view through the latch-side jamb
of the door with the door in the closed position, according to one
or more embodiments.
[0025] FIG. 13B is a cross-section view through the latch-side jamb
of the door with the door in a slightly opened position, according
to one or more embodiments.
[0026] FIG. 14A is a cross-section view through the hinge-side of
the door with the door in the closed position, according to one or
more embodiments.
[0027] FIG. 14B is a cross-section view through the hinge-side of
the door with the door in a slightly opened position, according to
one or more embodiments.
[0028] FIG. 15 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0029] FIG. 16 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0030] FIG. 17 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0031] FIG. 18 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0032] FIG. 19 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0033] FIG. 20 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0034] FIG. 21 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0035] FIG. 22 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0036] FIG. 23 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0037] FIG. 24 is a perspective view of a pod toy in a partially
assembled condition, according to one or more embodiments.
[0038] FIG. 25 is a perspective view of ridge of a pod toy,
according to one or more embodiments.
[0039] FIG. 26 is a perspective view of a pod toy with a door in an
open condition, according to one or more embodiments.
[0040] FIG. 27 is a perspective internal view of an inside face of
a door, according to one or more embodiments.
[0041] FIG. 28 is a cross-section view of an alternative corner or
joint, according to one or more embodiments.
[0042] FIG. 29 is a cross-section view of an alternative corner or
joint, according to one or more embodiments.
[0043] FIG. 30 is a perspective view of a pod toy, according to one
or more embodiments.
[0044] FIG. 31 is a perspective view of a pod toy, according to one
or more embodiments.
[0045] FIG. 32 is a perspective view of a pod toy, according to one
or more embodiments.
[0046] FIG. 33 is a perspective view of a pod toy, according to one
or more embodiments.
[0047] FIG. 34 is a cross-section view of an alternative corner of
joint, according to one or more embodiments.
[0048] FIG. 35 is a cross-section view of an alternative corner or
joint, according to one or more embodiments.
[0049] FIG. 36 is a cross-section view of an alternative corner or
joint, according to one or more embodiments.
[0050] FIG. 37 is an underside perspective view of the corner or
joint of FIG. 36, according to one or more embodiments.
[0051] FIG. 38 is a perspective view of a pod toy, according to one
or more embodiments.
[0052] FIG. 39 is a perspective view of a pod toy, according to one
or more embodiments.
[0053] FIG. 40 is a view of a blank foldable to form a wall and a
portion of a roof of a pod toy such as that shown in FIG. 1,
according to one or more embodiments.
[0054] FIG. 41 is a view of a blank foldable to form a wall and a
portion of a roof of a pod toy such as that shown in FIG. 1,
according to one or more embodiments.
[0055] FIG. 42 is a view of a blank foldable to form a wall and a
portion of a roof of a pod toy such as that shown in FIG. 1,
according to one or more embodiments.
[0056] FIG. 43 is a view of a blank foldable to form a wall and a
portion of a roof of a pod toy such as that shown in FIG. 1,
according to one or more embodiments.
[0057] FIG. 44 is a view of a blank foldable to form a door of a
pod toy such as that shown in FIG. 1, according to one or more
embodiments.
[0058] FIG. 45 is a view of a blank foldable to form a handle latch
of a pod toy such as that shown in FIG. 1, according to one or more
embodiments.
[0059] FIG. 46 is a view of a blank foldable to form corner trim of
a pod toy such as that shown in FIG. 1, according to one or more
embodiments.
[0060] FIG. 47 is a view of a blank foldable to form an inside
gable patch of a pod toy such as that shown in FIG. 1, according to
one or more embodiments.
DETAILED DESCRIPTION
[0061] The present application, in some embodiments relates to a
sustainably designed fort, hut, climbing device, or pod for use by
children to climb in, on, and/or around. In particular, the pod may
have a series of walls, some having windows or other openings, and
a roof. The pod may have a door for entering and exiting the pod
and the roof may include a roof opening allowing children to stand,
sit, or crouch within the pod and poke their head out of the
opening or even climb into and out of the pod using the opening.
The pod may be sized to accommodate younger children such as
toddlers and may be structurally sturdy so as to support the weight
of a child weighing up to 100 pounds, for example. The pod may be
constructed from sustainable materials commonly used for boxes,
carrying devices, or other containers and may be easily decorated
with markers, paints, or other common drawing or coloring
devices.
[0062] Referring now to FIG. 1, a pod 100 is shown. As shown, the
pod 100 may include a front wall 102, a back wall 104, a left
sidewall 106, and a right sidewall 108. The pod 100 may have a roof
constructed from portions of each wall that extend upwardly beyond
the wall to form a portion of the roof. The pod 100 may include a
front/left roof portion 110, a back/right roof portion 112, a
right/front portion 114, and a left/back portion 116. The
front/left roof portion 110 may extend from the front wall 102 and
form a front/left portion 110 of the roof. The back/right roof
portion 112 may extend from the back wall 104 and form a back/right
portion 112 of the roof. The right/front portion 114 may extend
from the right wall 108 and form a right/front portion 114 of the
roof. The left/back portion 116 may extend from the left wall 106
and form a left/back portion 116 of the roof. The portion of the
roof that is formed from a respective portion of a wall may be
evident from the figures where a fold line is present in lieu of an
interlocking seam.
[0063] Each of the walls of the pod 100 may take a shape defined,
in part, by the number of sides of the pod. In the case of a
4-sided pod, the walls may be 5-sided polygons as shown in FIGS.
3a-3d. Each wall may include a bottom edge 118, a vertically
extending left edge 120, a top/left gable edge 122, a top/right
gable edge 124, and a vertically extending right edge 126. (labeled
with A, B, C, and D depending on the FIG. in which they appear).
The bottom edge 118 may be a free edge having a left end and right
end. The left edge 120 may extend vertically from a bottom point at
the left end of the free edge 118 to a top point. The left edge 120
may be arranged substantially perpendicular to the free edge 118
and the left edge 120 may be configured for interlocking engagement
with a right edge 126 of an adjacent and out of plane wall to form
a corner seam. The top/left gable edge 122 may extend from an eave
point at the top point of the left edge 120 upwardly along a slope
to a peak end. The top/left gable edge 122 may define a gable slope
ranging from about 15 degrees to about 60 degrees, or from about 20
degrees to about 45 degrees, or a slope of about 30 degrees from
horizontal may be provided. The top/left gable edge 122 may be
defined by a fold line between the wall and a hingedly connected
roof portion. The top/right gable edge 124 may extend from a peak
end at the peak end of the top/left gable edge 122 downwardly along
a slope to an eave point. The top/right gable edge 124 may define a
gable slope equal and opposite the gable slope of the top/left
gable edge. In contrast to the top/left gable edge 122, the
top/right gable edge 124 may be configured for interlocking
engagement with a roof portion formed from an adjacent panel to
form a gable seam. The right edge 126 may extend vertically from a
top point at the eave point of the top/right gable edge 124 to a
bottom point at the right end of the bottom edge 118. The right
edge 126 may be arranged substantially perpendicular to the bottom
free edge 118 and the right edge 126 may be configured for
interlocking engagement with a left edge 120 of an adjacent and out
of plane wall to form a corner seam.
[0064] As indicated, each of the wall panels may have substantially
the same shape, size, and edge arrangements. Accordingly, each edge
may be discussed in more detail. As shown in more detail, in FIG.
8, the bottom edge 118 may be reinforced so as to be relatively
rigid and stiff. That is, without engagement by an adjoining out of
plane panel, the free bottom edge 118 may have a tendency to be
relatively flexible in a direction out of plane of the wall. The
free edge 118 may be reinforced as shown in FIG. 8. That is, the
free edge 118 may include an inwardly extending flange portion 128,
an upward sloping return portion 130, and a securing flap 132. The
flange portion 128 and return portion 130 may increase the section
modulus of the free edge 118 and, as such, it may be more resistant
to bending out of plane of the wall.
[0065] The left edge 120 and right edge 126 of each wall panel may
include a series of knuckles 134 configured for interlockingly
engaging knuckles on an adjacent intersecting edge. The knuckles
134 may also be configured for receiving a connecting pin or shaft
136 such that the several knuckles on adjoining edges may be
aligned by inserting the connecting pin or shaft 136 through a
series of aligned knuckles 134. As shown in FIG. 3, for example,
the left edge of each panel may include a notch 138 near the bottom
end extending to approximately the 1/4 point of the left edge 120.
The notch 138 may be followed by a knuckle 134 extending to
approximately the midpoint of the left edge 120. The knuckle 134
may be followed by another notch 138 extending to approximately the
3/4 point of the left edge 120 and another knuckle 134 may be
extend to the top end of the left edge 120. It is to be appreciated
that the lengths of the notches 138 and knuckles 134 may vary and,
as shown in FIG. 40, for example, a portion near the top of each of
the left and right edges may be free of knuckles 134 or notches 138
and, as such, the 1/4 point, midpoint, and 3/4 point may be
identified apart from this remaining portion. In contrast to the
left edge 120, the right edge 126 of each panel may have an
opposite pattern such that where a knuckle 134 is present on a left
edge 120, for example, a notch 138 is present on the adjoining
right edge 126 and vice versa. It is to be appreciated that other
approaches may be taken where not all of the panels are the same
and one panel has a first pattern along each edge and other panels
have a corresponding pattern along each edge. For example a front
and back panel may be the same and right and left panels may be
different from the front and back panels, but similar to each
other.
[0066] As shown in FIG. 10, each knuckle 134 may be formed from an
inwardly extending flange 140, a perpendicularly extending return
142, an outwardly extending return 144, an attachment flap 146, a
chamfer flange 148, and an outwardly extending closure flap 150.
The inwardly extending flange 140, perpendicularly extending return
142, and outwardly extending return 144 may be sized to form a
channel, bore, or sleeve 152 through the knuckle 134. In some
embodiments, as shown, the sleeve 152 may be substantially square
in cross-section and may be sized for a snug fit when the
connecting pin or shaft 136 is inserted therethrough. For example,
the width of the sleeve 152 may be slightly larger, substantially
equal to, or slightly smaller than an outer diameter of the
connecting pin or shaft 136 such that insertion of the connecting
pin or shaft 136 creates a friction fit between the pin 136 and the
inside surface of the knuckle 134. It should be appreciated that
portions of the cross-section of FIG. 10 may be continuous along
the length of the edge to reinforce the knuckles 134. For example,
the attachment flap 146, the chamfer flange 148, and the outwardly
extending closure flap 150 may be continuous between knuckles 134.
This may help maintain the knuckles 134 remain in general alignment
when a connecting pin 136 is not in place.
[0067] The top left edge 122 of each panel, as mentioned, may be
defined by a fold line between the wall and a hingedly connected
roof portion. For example, each of FIGS. 40-43 shows an inside
surface of a blank for use in forming a wall panel and the fold
line 154 for forming the top left edge 122 of each panel is shown.
Accordingly, a cross-sectional view through the top left edge 122
of each panel may simply include an upwardly extending portion of
the wall and an adjoining sloping roof portion connected thereto by
a living hinge type seam.
[0068] The top/right edge 124 of each panel may be somewhat similar
to the left and right edges in that it may include one or more
knuckles 134 for interlockingly engaging an adjoining roof portion.
As shown in FIG. 3a, for example, the top right edge of each panel
may begin with a notch 138 extending from the peak to about the 1/4
point as it extends downwardly along the top right edge 124. A
knuckle 134 may extend from the 1/4 point to about the midpoint and
another notch 138 may extend from about the midpoint to the 3/4
point and yet another knuckle 134 may extend the remaining length
of the top/right edge 124 leaving a last portion to extend to the
eave without a knuckle 134 or notch 138. It is to be appreciated
that the element configured for engagement with the top/right edge
124 is a gable edge of a roof portion of an adjacent panel and that
such an edge may have notches 138 and knuckles 134 sized and spaced
for interlockingly engaging the top/right edge 124.
[0069] As shown in FIG. 9, the knuckles 134 on the top/right edge
124 and the corresponding roof portion may be shaped slightly
differently than those on the left 120 and right edges 122 to
accommodate the slope of the roof. As shown, the knuckles may
include an inwardly and sloping flange portion 156, a parallel
extending return portion 158, and an outwardly and sloping return
portion 160. The knuckle 134 may also include an attachment flap
162, a chamfer flange 164, and an optional outwardly extending
closure flap (not shown). The knuckle 134 for the top/right edge
124 of the panel may, in some embodiments, be parallelogram shaped
in cross-section and may have width measured substantially
perpendicular to the wall that creates a friction fit with a
connecting pin or shaft 136. As with the knuckles 134 on the left
120 and right edges 126, portions of the cross-section in FIG. 9
may be continuous along the edge including the attachment flap 162
and the outwardly and sloping return portion 164. This may help
maintain the knuckles 134 in general alignment when a connecting
pin 136 is not in place.
[0070] Referring now to FIG. 4, a top view of the pod 100 of FIG. 1
is shown. As shown, each of four roof panels 110, 112, 114, 116 may
be substantially the same and each may extend from a respective
wall at a fold line. Collectively, the four roof panels may form a
generally pyramidal shape. As shown, however, the base of the
pyramid may be oriented approximately 45 degrees to the orientation
of the walls. That is, were the ridges of the roof structure
extended downward to the plane defined by the top end of the wall
joints and were the ridges extended upward to a top point of the
pyramidal shape, the base of the pyramidal roof structure would be
oriented approximately 45 degrees from the orientation defined by
the walls.
[0071] As shown, each roof panel may include an interlocking gable
edge 166, a ridge edge 168, a free roof opening edge 170, another
ridge edge 172 and a folded gable edge 174. (Only two panels have
been labeled for clarity, but each roof panel may have
corresponding edges labeled clockwise in each case and beginning
with the interlocking gable edge) The interlocking gable edge 166
may extend from an eave point upwardly along the slope of the
top/right gable edge 124 of an adjacent wall panel to a peak. The
ridge edge 168 may extend inwardly away from the peak and upward
toward a roof opening end. The free roof opening edge 170 may
extend away from the roof opening end of one ridge edge 168 to
another roof opening end of another ridge edge 172. The remaining
ridge edge 172 may extend therefrom downwardly along a slope from
the roof opening end to a peak of a gable. The remaining folded
gable edge 174 may extend downwardly from the peak to an eave where
it may end adjacent a eave end of the interlocking gable edge
166.
[0072] The interlocking gable edge 166 may be configured for
interlockingly engaging the top/right gable edge 124 of a wall
panel and, as such, may include alternating notches 138 and
knuckles 134 spaced and sized for interlocking with the notches 138
and knuckles 134 on the top/right gable edge 124 of a wall panel
and the knuckles 134 may have a cross-sectional shape similar to
that shown in FIG. 9.
[0073] The ridge edges 168, 172 may be configured for abutting an
adjacent ridge edge on an adjacent roof panel. As shown in FIG. 11,
each ridge edge 168, 172 may include an inwardly extending flange
portion 176, a return portion 178, and a securing flap 180. The
inwardly extending flange portion 176 may be configured to abut an
adjacent inwardly extending flange portion 176 of an adjacent roof
section.
[0074] The free roof opening edge 170 may be a stiffened edge
similar to the bottom edge 118 of the walls. However, in order to
accommodate the slope of the roof, the cross-section may be
slightly different. As shown in FIG. 12, the free roof opening edge
170 may include a inwardly extending flange portion 182, a return
portion 184, and a securing flap 186. In this case, the inwardly
extending flange portion 182 may be configured to be arranged
substantially vertically when the pod 100 is assembled and, as
such, substantially parallel to the walls of the pod 100.
[0075] As discussed with respect to the wall panels, the folded
gable edge 174 may be defined by a fold line between a wall panel
and an attached roof panel.
[0076] As shown in FIG. 6, the pod 100 may be assembled from four
substantially similar panels. As shown, with the exception of the
openings in the wall portion of a panel, each of the panels may be
substantially the same including a wall portion and a roof portion.
In some embodiments, one of the roof portions may include a tab or
slot for inserting a last connecting pin or shaft 136 along an
interlocking gable edge. However, the panels may otherwise be
substantially the same.
[0077] One of the panels for the pod may include a door 188 as
shown in FIG. 3d. The door 188 may be configured to open and close
through pivoting motion about a hinge, for example. The door 188
may include a substantially flat panel having a bottom edge 190, a
top edge 192, and two side edges 194, 196. The door 188 may have a
reinforced perimeter edge as shown in FIGS. 13-A, 13-B, 14-A, and
14-B. The reinforced perimeter edge may include a doubled over
portion 198, a inwardly extending sloping portion 200, an outwardly
extending sloping portion 202, and an attachment flap 204. The
inwardly extending sloping portion 200 and the outwardly extending
sloping portion 202 may form a substantially uniform triangular
cross-section extending around the perimeter of the door panel 188
creating a substantially stiff panel. As shown in FIGS. 13-A and
13-B, on the latch side of the door 188, the doubled over portion
198 of the door may be configured to releasingly abut an outer
surface of the wall panel on which the door 188 is positioned. As
shown in FIGS. 14-A and 14-B, on the hinge side of the door 188,
the doubled over portion 198 may be configured for securing the
door 188 to an outer surface of the wall panel on which the door
188 is positioned. A hinge crease 206 may be created on the door
between the doubled over portion 198 and the inwardly extending
sloping portion 200 to create a substantially flexible joint
extending the height of the door 188 on the hinge side and allowing
the door to flexibly pivot and, thus, open and close.
[0078] The wall panel with the door 188 may include a door opening
over which the door is positioned and the perimeter edge of the
door opening may be reinforced with an inwardly extending flange
208, a return portion 210 and an attachment flap 212. A handle or
closure device 214 may be positioned on the inside of the door 188.
The handle 214 may be positioned on the reinforced portion of the
door 188 and may be configured for frictionally engaging the flange
208 of the reinforced perimeter of the opening when the door 188 is
closed. A handle 214 may also be provided on the outside of the
door 188 or the door 188 may be sized such that it falls short of
the top of the wall opening near the top, such that the top edge of
the door can be grasped and pulled open as shown in FIG. 1.
[0079] Turning now to FIGS. 15-24, the assembly of a pod 100 may be
described. As shown in FIG. 15, four panels similar to those shown
in FIGS. 6 and 7 may be arranged to cause their respective left 120
and right wall 126 edges to interlockingly engage such that the
knuckles 134 on each edge are in alignment. Connecting pins or
shafts 136 may be inserted into the aligned set of knuckles 134
thereby securing the adjacent panels together while also aligning
the edges. In FIG. 15, a pair of connecting pins 136 are initially
inserted but not fully driven into position. In FIG. 16, these
connecting pins 136 are fully inserted. In FIG. 17, the first of
four roof panels is being put into position. As shown, a first roof
panel may be folded along the fold line relative to its respective
wall panel. The roof panel's gable edge 166 may be interlockingly
engaged with an adjacent panel's top/right gable edge 124 and the
knuckles 134 on each edge may be aligned with one another. As shown
in FIG. 18, a connecting pin or shaft 136 may be inserted through
the series of aligned knuckles 134. FIG. 19 shows the fully
inserted connecting pin 136. The remaining roof panels may be
folded into place and secured with connecting pins 136. Referring
to FIG. 20, the last roof panel may be folded into position.
However, it is to be appreciated that folding the last roof panel
into position may cause the series of aligned knuckles 134 to be
concealed below the first roof panel that was folded into position.
For this reason, a u-shaped slot 216 shown in FIG. 21 may be
provided to allow for insertion of the last connecting pin or shaft
136. As shown in FIG. 22, the connecting pin or shaft 136 may be
inserted and driven into position. FIG. 24 shows gluing of
reinforcing tabs across the ridge edges.
[0080] FIGS. 28 and 29 shown alternative options for connecting
pins or shafts 136. In one embodiment, pallet corner elements may
be used. In another embodiment, a folded and glued corrugated tube
may be provided. Still other shapes and types of connecting pins or
shafts 136 may be provided. As shown, the shape of the knuckle may
be adjusted for particular shapes of connecting pins or shafts to
provide for a friction fit of the respective shaft 136. In the
embodiments shown, the knuckle geometry is triangular, for
example.
[0081] FIGS. 30-33 show several different potential geometries for
the pod including a twelve sided pod with six panels, a six sided
pod with six panels, a five sided pod with five panels and an eight
sided pod with four panels having an igloo shape.
[0082] FIGS. 34 and 35 show alternative options for connecting the
vertical and gabled edges of the pod. That is, rather than using
interlocking aligned knuckles, a Velcro or other hook and loop
joint could be used between abutting flanges or tape may be used to
bridge the seams. In still other embodiments, a stapled approach
may be used as shown in FIGS. 36 and 37. It is to be appreciated
that the alignment provided by the knuckles with the connecting pin
inserted therethrough may provide for relatively well aligned
edges.
[0083] FIGS. 38 and 39 show additional options for a pod having six
or four sides and having a dome roof.
[0084] FIGS. 40-43 show panel blanks that may be used to create the
four panels of the pod. As shown, one embodiment may include
geometrically similar two-faced panels that may be differentiated
by the openings cut into the centers of the large panel faces
(door, large circle, shapes) (see FIG. 6) or the small tube access
cut out that allows for assembly (see FIG. 6).
[0085] In this embodiment, each panel may be stamped from a sheet
of corrugated cardboard, such that the edges of the panels may be
folded and fastened in place, forming the "knuckles" for the "piano
hinges," stiffening flanges, gabled edges, gabled corners, edges
for cutout shapes and other pre-assembly design details. FIGS.
40-43 show the flat, stamped shape of each of the four pentagonal
panels of one embodiment.
[0086] According to one embodiment, as shown in FIGS. 40-43, the
pod 100 may be constructed by folding and assembling four similar
cutout panels. Each panel may, in its flat unfolded condition
include two major faces 218, 220. The largest of the two major
faces 218 may be a generally pentagonal shape. The smaller of the
two major faces 220 may also be a generally pentagonal shape, and
this smaller face 220 may be attached to one of the five sides of
the larger face 218, with a creased or fold line 154 in between the
two faces 218, 220 to allow for folding and/or bending. When the
four panels of this embodiment are assembled, the larger pentagonal
face 218 of each of the panels may become an outer wall of the pod
100, and the smaller pentagonal face 220 of each of the panels may
form part of the roof.
[0087] One of the panels may now be described in detail and while
the flat blank of the panel is being described, the several edges
of the panel may be referenced based on their purpose and or
position in the constructed pod. For example a floor edge may
reflect it is an edge at or near the floor of the pod 100 when the
pod is constructed and a roof edge may reflect that it is an edge
at or near the roof. Still other similar naming conventions may be
used.
[0088] As shown in FIG. 40, for example, an inside face of a panel
is shown. The larger of the two major faces 218 may include two
roof edges 222, 224 that are substantially the same length and
shorter than the other three edges; two wall edges 224, 226 that
are substantially the same length, longer than the shorter edges,
and that lie parallel to one another; and a fifth floor edge 228
that is longer than the other four edges. Other relationships of
length may also be provided. The two roof edges 222, 224 may
generally form the top edge of the wall formed by the larger major
face 218 and each roof edge 222, 224 may extend across the top of
the pentagonal face at an angle ranging from approximately 15
degrees to approximately 45 degrees or from approximately 20
degrees to approximately 40 degrees or from approximately 25
degrees to approximately 35 degrees. The two roof edges 222, 224
may, thus, slope upward from the wall edges 226, 228 toward the
center of the panel and a peak when the two roof edges meet. The
two wall edges 226, 228 may generally form the side edges where
adjoining walls may be coupled to the larger major face 218. The
floor edge 230 may, thus, extend between the two wall edges 226,
228 and may be generally perpendicular to the wall edges 226, 228
for forming the bottom edge of the wall panel near the floor of the
pod when the pod is assembled. Various formations may extend from
each of the five edges of the larger major face 218. On one of the
shorter roof edges (i.e., edge 222) of the larger pentagonal face
218, the smaller pentagonal face may extend, with a fold line 154
along the border between the two pentagonal faces 218, 220. The
smaller pentagonal face 220 may be described in more detail
below.
[0089] On the other shorter roof edge (i.e., edge 224), two
generally rectangular structures 232 may extend outward from the
major face 218 to a free end. The long edges of the rectangular
shapes may be parallel to each other and generally perpendicular to
the roof edge 224. The rectangles may be substantially the same
length and width and may be spaced from one another by a distance
substantially equal to the width of the rectangular structures. At
the free ends of the two rectangles, a third rectangular shape 234
may be arranged extending across the ends of the two rectangles
with its long edges perpendicular to the first two rectangles and
parallel to the roof edge 222. One short edge of the third
rectangle may be flush with one long edge of the first rectangle.
The opposite short edge of the third rectangle may extend beyond
the second rectangle, and it may cut in toward the center of the
third rectangle at an angle forming a V-shaped and notched end 236.
At the base of one of the rectangles that is attached to the large
pentagonal face, a trapezoidal shape 238 may be positioned and
attached to a portion of the roof edge 222 of the pentagon and to
the long edge of the rectangle 232. That is, the rectangle 232 may
be inset from the end of the roof edge 222 and the trapezoid 238
may be positioned along the portion of the roof edge 222 that the
rectangle 232 is inset from. Two of the sides of the trapezoid may
be formed by the respective roof edge and rectangle and the
remaining three edges may be free edges as shown.
[0090] When the panels are folded, the two rectangles 232 along the
roof edge 222 of the pentagonal face 218 may each be folded three
times as shown by the fold lines. The three folds may dissect the
first and second rectangles along their long edges into four equal
segments. Each of the folds dissecting the first and second
triangles may be directed toward the large pentagonal face 218.
Another fold, directed away from the large pentagonal face, may be
made along the long edge of the third rectangle that joins the
first and second rectangles. The third rectangle may be folded once
along its length. The fold may begin at the point of the angle of
the cutout at one short edge of the third rectangle, and may be
folded in a direction away from the large pentagonal face. When the
first and second rectangles are each folded into four equal
segments, those four segments may form two "knuckles" of one half
of a piano hinge that will allow for connecting to another panel of
the roof of the complete pod. Part of the third rectangle may then
be attached to the large pentagonal shape to hold the shape of the
"knuckles." Where the fold is made along the length of the third
rectangle, the remaining portion of the third rectangle that is not
attached to the pentagonal face may be attached to the two
"knuckles" formed by the first and second rectangles, thus adding
stability to the "knuckles." A cross-section of the described folds
may be seen with reference to FIG. 9, for example.
[0091] The wall edges of the larger pentagonal face may align
parallel to one another at opposite sides of the pentagonal shape.
From one of these parallel edges may extend two rectangles 240,
with their long edges parallel to one another and parallel to the
floor edge 230 of the pentagonal face. The two rectangles may be
the same length and width, extend outwardly from the wall edge 228
to a free end, and have their respective long edges substantially
parallel to one another and substantially perpendicular to the wall
edges. At the free end of the rectangles, a third rectangular shape
242 may extend generally across the free ends of the two rectangles
240, with its long edges perpendicular to the first two rectangles
240 and parallel to the wall edge 228 of the pentagonal shape. One
short edge of the third rectangle may be flush with one long edge
of the first rectangle. The opposite short edge of the third
rectangle may extend beyond the second rectangle, and it may cut in
toward the center of the third rectangle at an angle forming a
V-shaped notch 244 in the end of the third rectangle. Extending
beyond the long edge of the third rectangle, furthest from the
pentagonal face, may be a fourth and fifth rectangle. The fourth
and fifth rectangles may be the same width as the first and second
rectangles, and align along the same plane as the first and second
rectangles. However, the fourth and fifth rectangles 246, 248 may
be shorter than they are wide. Thus, one long edge of the fourth
and fifth rectangles 246, 248 may lie along the long edge of the
third rectangle. A tab-forming notch may be provided near the base
of the fourth and fifth rectangles creating a tab for engaging the
pentagonal panel when folded. The two rectangles may be spaced from
one another forming a gap between them.
[0092] When the panels are folded, the first and second rectangles
240 along one of the wall edges of the pentagonal face may each be
folded three times. The three folds may dissect the first and
second rectangles 240 along their long edges into four equal
segments. Each of the folds dissecting the first and second
triangles may be directed toward the large pentagonal face. Another
fold, directed away from the large pentagonal face, may be made
along the long edge of the third rectangle that joins the first and
second rectangles. The third rectangle may be folded once along its
length. The fold may begin at the point of the angle of the cutout
at one short edge of the third rectangle, and may be folded in a
direction away from the large pentagonal face. When the first and
second rectangles 240 are each folded into four equal segments,
those four segments may form two "knuckles" of one half of a piano
hinge that will connect the walls of the complete pod. Part of the
third rectangle 242 may then be attached to the large pentagonal
shape to hold the shape of the "knuckles." Where the fold is made
along the length of the third rectangle 242, the remaining portion
of the third rectangle that is not attached to the pentagonal face
may be attached to the two "knuckles" formed by the first and
second rectangles, thus adding stability to the "knuckles."
Finally, a fold may be made along the long edge of the fourth and
fifth rectangles 246, 248 that connects to the third rectangle.
Upon assembly of the pod, the fourth and fifth rectangles 246, 248
may be attached to the "knuckles" of a second panel that joins at
this hinge location. A cross-section of the folded shaped may be
found, for example, in FIG. 10.
[0093] The second edge of the large pentagonal face that is
parallel and of the same length as the edge just described may have
similar extensions. The same structure consisting of five
rectangles may be located along this edge of the large pentagonal
face, but rotated 180 degrees. In addition, the V-shaped notch in
the extended end of the third rectangle may be omitted.
[0094] The floor edge 230 may include a generally trapezoidal shape
250 extending outwardly therefrom. The trapezoidal edge may be
folded to create a stiffened floor edge with a triangular
cross-section as shown in FIG. 8. The trapezoidal shape may be
provided to accommodate other panels being placed adjacent to the
present panel and create a mitered corner of the cross-sectional
shape of FIG. 8.
[0095] The smaller 220 of the two major panels, as mentioned, may
extend from one of the roof edges of the larger major panel. This
smaller panel 220 may be folded to form a portion of the roof as
shown in FIGS. 1-4. This smaller panel may be substantially
pentagonal having a first attached gable edge aligned with and
matching the roof edge of the larger panel. This attached gable
edge may define the fold line 154 between the larger major panel
and the present smaller major panel. The smaller major panel may
also have a free gable edge 252 extending generally outwardly from
the attached gable edge at a selected angle such that when the
smaller major panel is folded downward about the attached gable
edge, the free gable edge 252 will join with the gable edge of a
wall of an adjacent panel having a similar major pentagonal panel.
The angle at which the free gable edge 252 extends may be selected
taking into consideration the roof pitch defined by the major
pentagonal panels and the number of panels being used in the pod.
The free gable edge 252 may extend from the major panel outwardly
to a free end. At the free end of the free gable edge, a far ridge
edge 254 may extend substantially laterally from the free gable
edge 252. The far ridge edge 254 may extend at an angle selected to
allow the far ridge edge 254 to align with a near ridge edge,
described below, of an adjacent panel. The far ridge edge 254 may
be relatively short such that the opening in the top of the pod may
be accommodated. The far ridge edge 254 may, thus, extend a short
distance away from the free gable edge 252 to a roof opening edge
256. The roof opening edge 256 may extend away from the far ridge
edge 254 slightly back toward the major panel and at an angle to
the far ridge edge 254 such that a substantially square roof
opening may be provided as shown in FIG. 4. The roof opening edge
256 may be relatively long compared to the far ridge edge 254 and
may extend back toward the attached gable edge leaving a short
distance. A near ridge edge 258 may extend from the roof opening
edge 256 back to the attached gable edge closing the pentagon shape
of the smaller major panel 220. The near ridge edge 258 may return
to the attached gable edge at an angle selected to allow the near
ridge edge 258 to align with a far ridge edge 254 of an adjacent
panel when the panels are folded and the pod is assembled. Like the
free gable edge 252, this angle may depend on the roof pitch
selected and the number of panels used in the pod 100.
[0096] As shown, the free gable edge 252 may include a formation
extending outward therefrom similar to the formation extending from
the roof edge of the major pentagonal panel. That is, a pair of
rectangular elements 260 may extend outward with a third
rectangular element 262 extending across the ends. This formation
may be folded to form a piano hinge with knuckles as shown in FIG.
9, for example. Each of the far and near ridge edges 254, 258 may
include a substantially rectangular formation adapted for forming a
joint as shown in FIG. 11. The roof opening edge 256 may include an
inner rectangular formation and a trapezoidal formation adapted to
form a stiffened free edge as shown in FIG. 12 and accommodate the
intersection of the several edges of the opening at a mitered
corner.
[0097] It is to be appreciated that the panels of FIGS. 40-43 may
be substantially the same and for purposes of clarity, the
numbering on FIGS. 41-43 has been omitted, but the same or similar
elements are presumed to have a same or similar reference number.
Four of the described panel assemblies may be folded as shown in
FIG. 40. Each of the folded assemblies may be secured to adjacent
assemblies using pins 136 in the form of paper tubes, for example,
extending through the knuckle connections fainted by the folded
edges of the panels.
[0098] It is also to be appreciated that the indicia on the
patterns refers to folding up or down by a particular number of
degrees. As such, FIGS. 40-43 show how to fold a particular panel
into a wall/roof portion of the pod. Similarly, as shown in FIGS.
44-47, fold patterns are shown for other aspects of the pod
including the door, the handle, the corner trim, and the inside
gable patch, respectively.
[0099] The pod toy product may be designed for, but not limited to,
children 2-6 years of age. The pod may be constructed primarily of
corrugated cardboard and may be decorated with various craft
materials including crayons, paints, markers and various glued on
adornments. Additionally the pod may be used as an open-ended prop
for a variety of pretend play activities.
[0100] The basic configuration, as shown, may include an enclosure
with three child accessible openings. A door on one side, a
circular opening on a second side, and a square opening in the top
may be used by a child to enter or exit the enclosed space. Other
polygonal shapes may be used in alternate designs for access
openings. There may also be smaller openings that allow smaller
objects to be put into or ejected from the enclosure. (FIGS. 1.,
2., 3. & 4.)
[0101] At least some of the unique construction features of the pod
are intended to meet two goals not found in corrugated children's
products on the market today: abstract open-ended creativity and
exceptional product strength and longevity. First, the abstract
geometric design of the pod is intended to evoke the imaginations
of children to define the toy in a way that is personal. The
creative process of decorating and the creative imaginative play
functions are both open-ended and determined by the children
decorating and playing with the toy. Second, the pod is designed to
hold up to normal wear and tear and mild abuse and last for as long
as the toy is engaging to the child. The strength and durability of
the toy is intended to be more comparable to plastic toys on the
market than existing corrugated toys designed to last weeks.
[0102] The method of product assembly allows the pod product to be
packaged efficiently while reducing or minimizing shipping costs.
The use of paper tubes in the assembly simplifies the assembly
process and maximizes structural integrity to the finished
product.
[0103] Though future research may accommodate alternate materials
for these products, corrugated cardboard and paper tube were chosen
to satisfy the two main goals of creativity and sustainability. The
product may also be constructed of corrugated plastic sheet,
foam-core, wood, metal, structural foam molded plastic, injection
molded plastics or rotationally molded plastics. Each material may
cause alterations in some details of the design, but the same or
similar form and function may remain. The product may also be
constructed of a metal frame (e.g., extruded or formed aluminum)
and corrugated, wood or plastic panels.
[0104] Using corrugated cardboard provides a high level of creative
flexibility as virtually any arts and crafts material may be used
in the decorating process. The relatively light weight of the
material allows children to move and rotate the toy at will in
their self-driven creative play adventures. Corrugated cardboard
and paper tubes may be made using local natural resources and
containing relatively high amounts of recycled materials. The end
product and packaging are also recyclable and biodegradable.
[0105] The geometry of the pod may include four vertical pentagonal
side surfaces and four angled pentagonal top surfaces. Other
configurations were considered and may be used in other
permutations of the product. Examples of alternate configurations
are shown in attached illustrations (FIGS. 30., 31., 32. & 33.)
Some considerations for the geometry of the original design include
aesthetics, function, safety, structural integrity and ease of
assembly.
[0106] The product may be made from four geometrically identical,
or substantially identical, two-faced panels that are
differentiated only by the openings cut into the centers of the
large panel faces (door, large circle, shapes) (see FIG. 6). The
remaining panel with no such surface openings is differentiated by
a small tube access cut out that allows for proper assembly (see
FIG. 6). It is to be appreciated that the small tube access cutout
may be positioned in any of the panels and may affect the order in
which the panels are assembled.
[0107] Alternative designs may implement three, four, five, six or
eight geometrically identical panels designed as one, two or
three-faced panels (e.g. FIGS. 30., 31., 32., 33.). In these
examples, alternate panel attachment methods may be used as well as
different panel configurations.
[0108] The remaining pieces (i.e., in addition to the four
two-faced panels) may include two sets of four paper tubes (1''
ID.times.0.100'' wall thickness). One set of tubes may measure
15.5'' in length and the second set may measure 12'' in length. The
tubes may be used to hold the four panels together. The tubes may
be different diameters, lengths and wall thicknesses depending on
the design. In the present case, the longer tubes are used for the
wall joinery and the shorter tubes are used for the gable
joinery.
[0109] Several design details of the pod are advantageous to
building a toy that will last a reasonable lifespan, while
maintaining safety and optimizing function, aesthetics and value.
Several alternative designs were researched and some tested prior
to the design depicted in the figures.
[0110] The corner attachment on the vertical and gable corners
implement a "piano hinge" style of alternating corrugated sheet (44
ECT 3/16'' thick) wrap arounds, or square tube "knuckles" held
together by a paper tube (1' ID.times.0.100 wall thickness) (FIGS.
9. & 10.). Alternate designs included fabricating the
corrugated tube "knuckles" into hexagonal or octagonal shapes to
fit various tube sizes. Alternate designs for the tube were also
considered including standard pallet corners and corrugated sheet
formed into triangular or square tubes (see FIGS. 28 & 29).
Future product designs may implement these alternatives. Alternate
"non-piano hinge" joint designs were also considered including a
"Velcro Butt Joint Corner" (FIG. 34.), "Tape Butt Joint Corner"
(FIG. 35.) and "Trim Staple Butt Joint Corner" (FIGS. 36. &
37).
[0111] The design depicted and many of the alternate designs
include buttresses folded back around to support the wraparound
corrugated polygonal (square, parallelogram, octagon, triangle)
tubes. These buttresses act to position and shape the tube, add
strength to the overall structure and provide a cleaner interior
aesthetic.
[0112] Exposed edges and the abutted gabled edges of the panels may
be strengthened and stiffened by forming and gluing in place a
triangular (cross sectional) tube or gusseted stiffening flange.
These reinforcing stiffening flanges are mitered or trimmed to mate
up with adjoining panels. (See FIG. 8., FIG. 11. & FIG. 12).
The mitered corners of the base flanges also act to contain the
paper tubes used to connect the panels and create a smooth clean
bottom surface. (FIG. 5)
[0113] The pyramidal geometry of the top or roof of the Curio Pod
adds to the structural integrity of the assembly and avoids an
elevated horizontal surface that would be less safe. For example,
broad horizontal surfaces may become a convenient place to set
breakable objects or entice children that are too small to climb
onto them. The resulting corners of the pyramidal shape are obtuse
(less sharp) and are therefore less likely to cause accidental
minor injuries. Alternative roof designs include a domed roof
(FIGS. 38. & 39) for any polygonal construction (square,
pentagonal, hexagonal, etc.) as well as the designs already shown
(FIGS. 30-33).
[0114] The top seams of the pod may be secured and sealed by outer
trim pieces and inside gluing flaps made from thinner "E Flute" (
1/16'' thick) corrugated cardboard. These gluing tabs may be glued
together by the customer in the final steps of the assembly
process. Other materials and designs for the trim and gluing flaps
were tested and may be used in the future. The four inside gluing
flaps (FIG. 23) may be glued first to hold the four top seams
together. The interlocking outer trim tabs (FIG. 24 & FIG. 25)
may be glued to further secure the top seams completing the
assembly of the pod. Alternate methods could also be used to seal
these seams including: Velcro or other hook and loop products,
pressure sensitive adhesive (PSA) (FIG. 34), paper tape (FIG. 35)
or staples (FIGS. 36 & 37).
[0115] Details of the Curio Pod door design may provide strength,
safety and ease of operation (FIG. 1, FIG. 44, FIG. 26 & FIG.
27). Folding over the corrugated material and gluing creates a
double thick door hinge flap, which is glued to the reinforced
framed opening of the pod (FIG. 14-A & FIG. 14-B). Around the
inside perimeter of the door, a beveled frame may be provided to
provide stiffness and strength while eliminating potential finger
pinch points. The outer end corners of the door may be rounded for
safety. The 3/4'' gap at the top of the door may function as an
outer handle for opening as well as a mail slot or peek out (FIG.
26 & FIG. 27). An alternate hinge method may be used employing
the "piano hinge" method of alternating corrugated sheet wrap
arounds, or square tube "knuckles" held together by a paper tube.
Similar to the design used to attach the corners of the Curio Pod.
The size of the "knuckles" and paper tube diameter may be smaller
in the hinge design than in the corner attachments.
[0116] The Handle/Closure employs an interference fit between the
panel opening frame and the protruding handle legs (FIG. 13-A &
FIG. 13-B). The shape of the handle mounted to the 45.degree.
beveled frame surface allows the curved sides of the handle to
slide into the side of the panel frame with enough friction to keep
the door closed. The friction fit may then easily be overcome by a
child to open the door. The handle may be folded over and glued to
be double thick to increase strength and improve function (FIG.
45).
[0117] The pod was designed to be packed into an economical
shipping package while allowing for easy assembly by the customer
resulting in a product with superior structural integrity. The four
similar folding panels may be held together using sturdy paper
tubes (1'' ID.times.0.100'' wall) to join both the four vertical
corners and the top gable corners. The tubes may allow for easy
assembly while adding strength to the overall structure (FIG. 6
& FIG. 7). The four vertical tubes (FIG. 15 & FIG. 16) are
contained when the four top panels are attached using the shorter
paper tubes (FIGS. 17, 18, 19 & 20). The final tube may be
installed in the top by folding back a "U" shaped tab in the corner
of one of the top panels (FIG. 21 & FIG. 22). This opening may
then be covered and sealed in the final gluing assembly. The final
steps of gluing the inside flaps and outer trim tabs solidifies the
structure and creates a safe toy free of accessible gaps (FIG. 23
& FIG. 24).
[0118] The corrugated cardboard pieces of the pod may be stamped
out using the latest corrugated die-cutting manufacturing
processes. The pieces may then be folded and glued into shape by
hand with the aid of assembly fixtures. Design details including:
relief radii, rounded corners, clearances, locator flanges, mitered
corners and perforated back-folds may be implemented to ease
assembly and improve durability, safety and strength. The cut out
patterns of the four panels may include inside radii for all of the
openings to relieve stress on the folded corners and resist tearing
(FIG. 41.-43.). These include the four rectangular openings and
three partial rectangular cut-outs that form the wrap around
knuckles on the edges of all four panels. The door opening, large
circle opening and small shapes openings implement inside cut radii
between the flaps also. Two small flanges on both sides of each
panel may serve to position the vertical wrap around knuckles in
the manufacture assembly process. These four tabs implement radius
notches and a perforated crease to prevent tearing on the back
fold.
[0119] Various embodiments of the present disclosure may be
described herein with reference to flowchart illustrations and/or
block diagrams of methods, apparatus (systems), and computer
program products. It is understood that each block of the flowchart
illustrations and/or block diagrams, and/or combinations of blocks
in the flowchart illustrations and/or block diagrams, can be
implemented by computer-executable program code portions. These
computer-executable program code portions may be provided to a
processor of a general purpose computer, special purpose computer,
or other programmable data processing apparatus to produce a
particular machine, such that the code portions, which execute via
the processor of the computer or other programmable data processing
apparatus, create mechanisms for implementing the functions/acts
specified in the flowchart and/or block diagram block or blocks.
Alternatively, computer program implemented steps or acts may be
combined with operator or human implemented steps or acts in order
to carry out an embodiment of the invention.
[0120] Additionally, although a flowchart may illustrate a method
as a sequential process, many of the operations in the flowcharts
illustrated herein can be performed in parallel or concurrently. In
addition, the order of the method steps illustrated in a flowchart
may be rearranged for some embodiments. Similarly, a method
illustrated in a flow chart could have additional steps not
included therein or fewer steps than those shown. A method step may
correspond to a method, a function, a procedure, a subroutine, a
subprogram, etc.
[0121] As used herein, the terms "substantially" or "generally"
refer to the complete or nearly complete extent or degree of an
action, characteristic, property, state, structure, item, or
result. For example, an object that is "substantially" or
"generally" enclosed would mean that the object is either
completely enclosed or nearly completely enclosed. The exact
allowable degree of deviation from absolute completeness may in
some cases depend on the specific context. However, generally
speaking, the nearness of completion will be so as to have
generally the same overall result as if absolute and total
completion were obtained. The use of "substantially" or "generally"
is equally applicable when used in a negative connotation to refer
to the complete or near complete lack of an action, characteristic,
property, state, structure, item, or result. For example, an
element, combination, embodiment, or composition that is
"substantially free of" or "generally free of" an ingredient or
element may still actually contain such item as long as there is
generally no measurable effect thereof.
[0122] In the foregoing description various embodiments of the
present disclosure have been presented for the purpose of
illustration and description. They are not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Obvious modifications or variations are possible in light of the
above teachings. The various embodiments were chosen and described
to provide the best illustration of the principals of the
disclosure and their practical application, and to enable one of
ordinary skill in the art to utilize the various embodiments with
various modifications as are suited to the particular use
contemplated. All such modifications and variations are within the
scope of the present disclosure as determined by the appended
claims when interpreted in accordance with the breadth they are
fairly, legally, and equitably entitled.
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