Systems and methods for building an interlocking decorative house
A special tabbed pattern is integrated into a series of forms. The forms may be cookie cutters adapted to cut baked dough or other material set to desired density to provide a series of panels corresponding to the cutters. Alternatively, the forms may be molds, e.g, adapted to receive melted chocolate which is allowed to cool and set to form a series of panels corresponding to the molds. The panels are adapted to be joined together to form a decorative structure. The tabs are sized and positioned to provide a dovetail joint along each edge of the structure. The protruding tabs or ends are of a slightly smaller dimension than the notches that they fit inside of to provide a secure fit. This self-interlocking design allows each individual piece of the structure to be fitted together, one at a time, while maintaining an acceptable degree of stability throughout the assembly process.
This application is a divisional of co-pending U.S. application Ser. No. 10/750,700 filed 2 Jan. 2004 and entitled “Interlocking Assembly System and Related Methods for a Decorative House” which claims the benefit of provisional Application Ser. No. 60/437,708, filed Jan. 2, 2003, and entitled “Interlocking Assembly System and Related Methods for a Decorative House.”
FIELD OF THE INVENTIONThe invention relates to the construction of decorative houses.
BACKGROUND OF THE INVENTIONDecorative structures, particularly edible decorative structures, such as gingerbread houses, are well-known. Such structures are routinely made and displayed, especially for specially occasions, such as birthdays or Christmas. Children, in particular, enjoy participating in the decorating process. Historically, assembly of a gingerbread house has been an awkward and time-consuming task. Icing, in particular icings having an egg white base, such as royal icing, have traditionally been used to bond the individual panels of a structure together. The icing method is difficult to implement due to the amount of drying time required. Gingerbread house builders typically need a great degree of patience and may rely upon some sort of makeshift propping system to help stabilize the structure while the icing is setting. The icing assembly method can therefore be a frustrating experience for both adults and children. The frustration often limits enjoyment of the finished structure and may even prevent completion of the structure.
The need therefore remains for systems and methods for creating a decorative structure that are time and cost-efficient. The need further remains for systems and methods that permit ease of assembly while maintaining an acceptable degree of stability throughout the assembly process.
SUMMARY OF THE INVENTIONA special tabbed pattern is integrated into each joining panel of a decorative structure. The tabs are sized and positioned to provide a dovetail joint along each edge of the structure. The protruding tabs or ends are of a slightly smaller dimension than the notches that they fit inside of, thus providing a secure fit. This self-interlocking design allows each individual piece of the structure to be fitted together, one at a time, while maintaining an acceptable degree of stability throughout the assembly process.
One aspect of the invention provides a kit for creating a decorative structure. The kit provides a plurality of pre-made or pre-cut panels and a decorating material. The panels provide a series of tabs and notches that are adapted to interlock the panels. In one embodiment, the kit comprises a pair of end panels, a pair of side panels, a pair of roof panels, and a decorating material. Each end panel has a bottom surface, a pair of opposed side surfaces each having a tab and a notch, and a pair of inclined top surfaces each having a tab and a notch. Each side panel has a top surface, a bottom surface, and a. pair of opposed side surfaces, each side surface having a tab and a notch. Each roof panel has a top surface, a bottom surface, and a pair of opposed side surfaces, each side surface having a tab and a notch.
Another aspect of the invention provides a kit for creating a decorative structure. The kit comprises a plurality of edible panels. The panels provide a series of tabs and notches adapted to interlock the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention that may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
I. Interlocking Panels
The cutter 10 may be made of any suitable food safe material, e.g., 18 g stainless steel. Desirably, the cutter 10 includes a tab or knob 26 for easy grasping and manipulation.
The tab 22 of a first panel 18 is sized and configured to interlock with a complementary notch 20 on a second panel 18 and the notch 20 of the first panel 18 is sized and configured to interlock with a complementary tab 22 on the second panel 18 to form a series of interlocking panels 18.
In the embodiment shown in
The tabs or ends 22 are desirably of a slightly smaller dimension than the notches 20 that they fit inside of the notches 20, thus providing a secure fit, similar to a jigsaw puzzle. The cutter 10 may be provided in virtually any regular or irregular geometric size and shape. It is apparent that a series of cutters 10 of different configurations may be provided to form a series of corresponding panels 18 to create virtually any pattern.
II. Creation of a Decorative Structure Using
A Series of Interlocking Panels
The interlocking assembly system may also be used in creating a variety of non-planar or three-dimensional structures. The system provides a custom engineered, self-supportive design that enables a person to easily join together the individual elements of the decorative structure. The system is particularly well suited for constructing an edible structure, e.g., a gingerbread house. Therefore, the system and methods will be described in accordance with the construction of an edible structure.
The interlocking assembly method may be offered to the consumer in the form of a “make it from scratch” kit or a “prepared, ready to assemble” kit, and may be integrated into any type of food-cutting or food-shaping apparatus that is used to create a food structure, particularly, a cookie house. A cutting or shaping apparatus that utilizes the interlocking assembly method may be provided in virtually any regular or irregular geometric size and shape so that the components of the structure, when assembled, may resemble any type of structure or building, such as a house.
The kit 28 provides an end panel cookie cutter 32, a roof panel cookie cutter 34, and a side panel cookie cutter 36. Cutters 32/34/36 act as a form for creating, respectively, a pair of end panels 38, a pair of roof panels 40, and a pair of side panels 42, as will be described in detail later (see also
In some cases, the cook or baker may wish to provide his or her own recipe. Desirably, a specially formulated recipe is provided, with at least some of the ingredients supplied as part of the kit 28 in the form of mix 44. For example, in one embodiment, the mix 44 provides pre-measured dry ingredients, e.g., flour, sugar, and spices. The baker need only add a few fresh ingredients, much like a dry cake mix from the supermarket. Fresh ingredients may include, but are not limited to, eggs, molasses, and butter. The custom-blended, pre-packaged, dry cookie mix 44 eliminates the need to have the required dry ingredients on hand, as well as the need to measure and blend each ingredient accordingly. The cookie mix 44 may be provided in any desired type or flavor, e.g., gingerbread, chocolate, shortbread. To maximize cost efficiency, the mix 44 may also be sold or provided separately from kit 28 to permit reuse of other kit 28 components.
With reference now to
As seen in
It is to be understood that the gauges 40 and cutters 32/24/36 are specifically engineered to work together to ensure that the required thickness is established and evenly maintained from panel 32/24/36 to panel 32/24/36, therefore guaranteeing that the baked, cutout panels 32/24/36 fit properly together. The dough 52 may be flattened and rolled directly on a greased cookie sheet 56. The cookie sheet 56 becomes the work surface, rather than a bread board or counter, making clean-up easier and quicker.
The gauges 46 enable the baker to roll the dough 52 a uniform desired thickness. The desired thickness may vary by the material being used. For example, in a representative embodiment, the dough 52 is gingerbread dough rolled approximately ⅜inch thick.
The gauges 46 may be variously constructed. The size and configuration of the gauges 46 may be customized, e.g., for use with different types of dough 52 and for specific baking operations. In the illustrated embodiment, the gauges 46 take the form of a pair of elongated rectangular rods. The gauges 46 may be made of any suitable food safe material, e.g., wood, metal, plastic. In a preferred embodiment, the gauges 46 are made of a food safe acrylic material that is washable to permit reuse. The gauges 46 are desirably built to a specified height to consistently roll the dough 52 to a uniform desired thickness. In a representative embodiment, each gauge 46 is 12 inches long, 3/16to 4/16inch high and ½inch wide.
In an alternative embodiment, seen in
The rolled dough 52 is baked as rough, oversized shapes at the temperature and time period instructed. The specified time and temperature will vary according to the type of dough 52 being used, as well as the type and size of cookie sheet 56 being used. The dough 52 is set or hardened to a cookie by the baking operation.
With reference to
In one alternative embodiment, seen in
Alternatively, instead of pan 68, melted chocolate 66 may be poured into a series of chocolate molds, eliminating the need for cutters 32/34/36. As seen in
Each cutter 32/34/36 may include a knob 26, e.g., ¼inch diameter, centered on cutter 32/34/36, for easy grasping as previously described. Desirably, the outer edges of the cutters 32/34/36 include a bend down of approximately 90° to form a peripheral cutting surface 72 (see
When dimensioned according to the above representative embodiment, four standard size 14 in.×16 in. cookie sheets 56 can accommodate the necessary panels (two end panels 38, two roof panels 40, and two side panels 42) in the arrangement illustrated in
However, most standard ovens will not readily accommodate four cookie sheets 56 at one time and therefore at least 20 two baking operations may be required. Alternatively, one professional size 13 ½in.×17 in. cookie sheet 56 can accommodate one end panel 38, one roof panel 40, and one side panel 42. In this arrangement, only two cookie sheets 56 are required. The two cookie sheets 56 are readily accommodated in most standard ovens, cutting baking time in half and reducing cleanup.
This above-described sequence of baking steps, in conjunction with the use of furnished ingredients and prepping equipment will provide easy and successful creation and assembly. The interlocking assembly method provides the means for a baker to easily create and assemble an edible structure 30 that they have made from scratch. The tabbed pattern allows each individual panel 38/40/42 of the structure 30 to be fitted together, one at a time, while maintaining an acceptable degree of stability throughout the assembly process.
In assembling the structure 30, a side panel 42 is interlocked with an end panel 38, as shown in
In a similar manner, the second side panel 42 is then interlocked with the end panel 38, as shown in
As
The assembled structure 30 is then decorated as desired. Preferably, suggested designs are included in the instructions 50 for the consumer's reference. The decorating step can be an expensive one as several types of packaged confectionary products are typically purchased to achieve greater detail and uniqueness in the finished product. Therefore, the kit 28 desirably includes the decorating accessories 48, thereby greatly simplifying the process as well as making it more cost-effective. The decorating accessories may include a variety of confectionary products, such as icing (e.g., microwavable chocolate), nuts, coconut, cookies, etc. The icing serves to further bond the panels 38/40/42 together, thereby providing additional stability to the finished structure 30.
Non-bakers or those short on time may wish to place greater emphasis upon the decorating process. Children, in particular, will derive a great entertainment value from the assembly and decorating process alone. Therefore, a series of pre-baked and pre-cut panels 38/40/42, which may be cookie, solid chocolate or some other type of edible or non-edible substance as previously noted, may be provided to the consumer in the form of a “prepared, ready to assemble” decorating kit 28A, shown in
Some users may desire that the structure 30 provide additional aesthetic elements. For example, in an alternative embodiment illustrated in
In the illustrated embodiment, the assembled structure 30 comprises first and second end panels 38, first and second roof panels 40, and first and second side panels 42. It is contemplated that the structure 30 may be varied by providing a greater or lesser number of top, end, or side panels 38/40/42 to create a structure 30 of virtually any configuration. In one alternative embodiment, a floor panel can be provided (not shown).
As seen in
When dimensioned according to this representative embodiment, the necessary panels (two end panels 138, two roof panels 140, and two side panels 142) can be accommodated on a single standard 14 in.×16 in. cookie sheet 56.
Cutters 132/134/136 have a tabbed arrangement similar to the embodiment illustrated in
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
Claims
1. A kit for creating a decorative structure comprising:
- a pair of end panels, each end panel having a bottom surface, a pair of opposed side surfaces each having a tab and a notch, and a pair of inclined top surfaces each having a tab and a notch,
- a pair of side panels, each side panel having a top surface, a bottom surface, and a pair of opposed side surfaces, each side surface having a tab and a notch, and
- a pair of roof panels for the house, each roof panel having a top surface, a bottom surface, and a pair of opposed side surfaces, each side surface having a tab and a notch,
- the end panels, roof panels, and side panels interlocking to form the structure.
2. A kit as in claim 1, further comprising instructions for use.
3. A kit as in claim 1 wherein at least one of the end panels, side panels, or roof panels comprises an edible material.
4. A kit as in claim 1 wherein at least one of the end panels, side panels, or roof panels comprises a non-edible material.
5. A kit as in claim 3 wherein said edible material comprises a cookie material.
6. A kit as in claim 1, further comprising a decorating material.
7. A kit as in claim 6 wherein at least a portion of said decorating material further comprises an edible material.
8. A kit as in claim 6 wherein at least a portion of said decorating material comprises a non-edible material.
9. A kit for creating a decorative structure comprising:
- a plurality of panels, the panels providing a series of tabs and notches adapted to interlock the panels, and
- a decorating material.
10. A kit as in claim 9
- wherein at least one of the panels comprises an edible material.
11. A kit as in claim 9
- wherein at least one of the panels comprises a non-edible material.
12. A kit as in claim 9, further comprising instructions for use.
13. A kit as in claim 9
- wherein the panels are adapted to interlock to form a three-dimensional structure.
14. A kit as in claim 9 wherein at least a portion of said decorative material comprises an edible material.
15. A kit as in claim 9 wherein at least a portion of said decorative material comprises a non-edible material.
16. A kit for creating a decorative structure comprising
- a plurality of edible panels, the panels providing a series of tabs and notches adapted to interlock the panels.
17. A kit as in claim 16, further comprising instructions for use.
18. A kit as in claim 16, further comprising a decorating material.
19. A kit as in claim 16 wherein the panels are adapted to interlock to form a three-dimensional structure.
20. A kit as in claim 18 wherein at least a portion of said decorative material comprises an edible material.
21. A kit as in claim 16 wherein the edible panels further comprise a cookie material.
Type: Application
Filed: Apr 30, 2007
Publication Date: Aug 30, 2007
Inventor: Debra Kolz (Grafton, WI)
Application Number: 11/799,006
International Classification: A23L 1/48 (20060101);