CARDBOARD PLAY STRUCTURE
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.
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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.
BACKGROUNDPlay 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.
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.
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 DISCLOSUREIn 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.
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.
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.
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.
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.
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.
Referring now to the figures and more particularly to
The car assembly may come in variety of sizes, for all ages of users, one particular embodiment has packaged dimensions of about 54″L×29.5″H×1.75″W and unpackaged dimensions of 53.5″L×27″H×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/4×4, 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.
With reference to
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) (
As illustrated in
As illustrated in
As illustrated in
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. (
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.
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″×29.5″H×1.65″W and unpackaged dimensions of 53.5″L×27″H×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.
To connect the nose of the jet, the sides of the body are folded downwardly as illustrated in
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
The fully assembled form of the exemplary corrugated cardboard jet plane is displayed in
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×30.5″H×2″W and unpackaged dimensions of 46″L×31.5″H×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.
In a first exemplary embodiment, the columns 175 of the side body panels (J) are folded inwardly, such as to create support columns (
Referring back to
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
One embodiment of a fully assembled stand, complete with an awning and sign is illustrated in
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.
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.
Type: Application
Filed: Nov 2, 2010
Publication Date: Nov 17, 2011
Applicant:
Inventors: Michael Welsh (Gates Mills, OH), Andy Carcioppolo (Chesterland, OH), Sam Cahill (Cleveland, OH)
Application Number: 12/917,709
International Classification: A63H 3/52 (20060101);