The present invention relates to base sheets of stiff sheet material for forming various three-dimensional articles, and also to kits including such base sheets. The invention is particularly useful for forming various three-dimensional articles using corrugated cardboard in a “do it yourself” manner, and is therefore described below with respect to such an application.
Corrugated cardboard sheets have widely been used in constructing inexpensive, light-weight containers, as well as other types of articles in a “do it yourself” manner. Examples of cardboard kits for constructing various articles of furniture, particularly for children, are described in U.S. Pat. Nos. 4,067,615, 4,934,256 and 6,083,580. However, such kits have not yet found widespread use because of the difficulty in designing the base sheets, as well the other elements of the kit, in such form as to permit them to be supplied in a compact flat condition for shipping, handling or storage, and to be folded in a quick and facile manner to form a three-dimensional article which has dimensional stability, structural rigidity and a pleasing appearance.
An object of the present invention is to provide a base sheet of stiff sheet material, particularly corrugated cardboard, and also a kit including such a base sheet, for use in forming three-dimensional articles having advantages in one or more of the above respects.
According to a broad aspect of the present invention, there is provided a base sheet of stiff sheet material cut according to a predetermined configuration, and including a predetermined arrangement of fold lines to enable the base sheet to be foldable from a flat condition to a three-dimensional condition defining an article having a polygonal bottom wall circumscribed by a plurality of erect side walls; the predetermined arrangement of fold lines including: (a) a plurality of fold lines in the central region of the base sheet to define the bottom wall on the inner side of the fold lines and the side walls on the outer side of the fold lines; and (b) a fold line midway in each side wall to define an outer section of the side wall foldable over an inner section of the side wall; the outer section of each side wall, when folded over the inner section of the respective side wall, including an outer edge engageable with the bottom wall to firmly retain the respective side wall erect in the three-dimensional condition of the article and to expose for view a folded edge, rather than a cut edge, of each side wall.
According to further features in the described preferred embodiment, the base sheet is formed with recesses in the central region inwardly of the fold lines defining the bottom wall; and the outer edge of the outer section of each of the side walls is formed with a projection receivable in the recesses when the outer sections are folded over the inner sections to firmly retain the side walls erect. In addition, the base sheet is cut, and is formed with further fold lines, to define a bendable flap on each of the inner sections of alternative side walls, each flap being insertable between the inner and outer sections of the adjacent side wall, to more firmly retain all the side walls in an erect position in the three-dimensional condition of the article. In addition, the base sheet is
Two embodiments of the invention are described below for purposes of example, in which the three-dimensional article is of rectangular configuration, and the base sheet is of corrugated cardboard.
In one described embodiment, the base sheet is included in a kit which kit also includes a partition, preferably a plurality of partitions, to be applied between two opposed side walls of the three-dimensional article when in is three-dimensional condition. Each partition is defined by another sheet of cardboard bent over itself at a mid-portion thereof to expose for view only the folded edges, and not cut edges, and also to define two parallel sections, each formed with a bendable flap at its opposite ends each receivable between the inner and outer sections of one of the opposed side walls. The outer sections of the two opposed side walls are each formed with a slot for receiving the partition sheet with the flaps of the partition received between the outer and inner sections of the respective side wall.
In another described preferred embodiment, the flaps on the inner sections of the alternate side walls receivable within the inner and outer sections of the adjacent side walls include interengaging ribs and recesses. In addition, the inner sections of the side walls formed with the flaps, and the outer sections of the adjacent side walls, include interengaging ribs and recesses. Such a construction firmly retains the outer sections of all of the side walls in an erect position with respect to the bottom wall in the three-dimensional condition of the article, with the folded over outer sections concealing these interengaging ribs and recesses, thereby presenting a neat appearance.
The latter embodiment is particularly useful as a modular unit, for assembly with a plurality of like modular units in the form of a wall-mounted or floor-mounted shelving or bookcase.
As will be described more particularly below, base sheets constructed in accordance with the foregoing features of the invention may be produced in volume and at low cost, may be packaged and shipped in a compact flat condition, and may be used for assembling in a “do it yourself” manner, a wide variety of three-dimensional articles, particularly open cabinets, partitioned containers, bookcases, shelving and the like, having a high degree of dimensional stability and structural rigidity, and also presenting a very pleasing appearance.
Further features and advantages of the invention will be apparent from the description below.
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
a-8i illustrate the sequential steps used in forming, from the components of the kit of
a-14d illustrate the sequence of operations involved in using the base sheet of
a,
15
b and 15c illustrate how the article of
a,
16
b.,
17
a,
17
b and 18a, 18b illustrate other variations in the modular units of
and
It is to be understood that the foregoing drawings, and the description below, are provided primarily for purposes of facilitating understanding the conceptual aspects of the invention and possible embodiments thereof, including what is presently considered to be a preferred embodiment. In the interest of clarity and brevity, no attempt is made to provide more details than necessary to enable one skilled in the art, using routine skill and design, to understand and practice the described invention. It is to be further understood that the embodiments described are for purposes of example only, and that the invention is capable of being embodied in other forms and applications than described herein.
As indicated earlier, the invention provides a base sheet, or a kit including such a base sheet, which is cut according to a predetermined configuration and includes a predetermined arrangement of fold lines, to enable the base sheet to be folded in a particular three-dimensional article. The base sheet may thus be supplied alone, or as a component of a kit. It can be produced, shipped and stored in a compact flat condition, and then used by the purchaser to form, in a quick and facile manner, three-dimensional articles having high dimensional rigidity and structural stability, and also a pleasing appearance.
Two embodiments of the invention are described below for purposes of example.
i illustrate the invention embodied in a base sheet, and also in a kit including such a base sheet, to be used for producing a cabinet, partitioned receptacle, or the like, as illustrated in
The three-dimensional article illustrated in
As shown in
As further seen in
Each partition is further formed with a slot, 106f, 107f, for accommodating the longitudinal partition 108.
The longitudinal partition 108 (
The construction of the base sheet 110 is also illustrated in
Cardboard sheet 111 is of rectangular configuration and serves as the bottom wall 105 of article 100. Sheets 112-115 are adhesively joined at their inner edges 112a-115a, to the under surface of sheet 111. They are formed with fold lines 112b-115b, to permit these sheets to be bent upwardly to an erect condition with respect to the bottom sheet. Each of the sheets 112-115 is formed with a further fold line, e.g., 112c midway of its length to permit the sheet to be folded into an inner section, e.g., 112d, and an outer section, e.g., 112e.
The two cardboard sheets 112, 113 which, as indicated earlier, constitute the longitudinal sides 102 and 103 of article 100, are formed, in their outer sections, with three equally-spaced slots, e.g., 112f, for accommodating the three intermediate transverse partitions 107; whereas the outer sections of sheets 114, 115, which define the transverse side walls of article 100, are provided with a single middle slot, e.g., 114f, to accommodate the longitudinal partition 108.
As further seen in
In addition, the inner section of each sheet 112, 113, is formed on each of its opposite ends with an extension, e.g., 112h, separated by a fold line, e.g., 112i, defining bendable flaps. As will be described below, these flaps are insertable between the inner and outer sections of the adjacent side walls (namely those defined by sheets 114, 115) to more firmly secure all the side walls in an erect position in the three-dimensional condition of article 100.
The two sheets 114, 115 defining the transverse side walls 104, 105 of article 100, are each formed, in their outer sections, with a single slot 114f, 115f, and with two projections 114g, 115g on each side of respective slot also engageable with recesses in the bottom wall. In addition, the inner sections of the two sheets 114, 115 are also formed with end flaps 114i, 115i; these are adhesively coated so as to enable them to be folded against, and adhesively joined, to the inner surfaces of the respective side wall sections for reinforcement purposes.
The two further cardboard sheets 116, 117 illustrated in
Sheet 118 illustrated in
It will be seen that when sheet 118 is folded along its fold lines and adhesively joined at its outer sections 118b to sheet 111, the middle sections 118e are forced to an erect position in folded relation to each other to constitute the longitudinal partition 108, with the folded edge along fold lines 118a exposed for view (rather than a cut edge), and with the slots 108f for receiving the transverse partitions 106.
a-8i illustrate the sequence of operations involved in assembling the three-dimensional article 100 illustrated in
The three-dimensional article 200 illustrated in
As shown in
Thus, as shown in
Base sheet 210 includes a further top sheet 226 which is adhesively joined over the upper surface of the central sheet 221. Top sheet 226 is similarly formed with a cut-out 226a in one corner to be in alignment with cut-out 221a of the central sheet 221 when sheet 226 is adhesively joined to sheet 221. The corrugations in sheet 226 are perpendicular to those in sheet 221 for strengthening purposes. In addition, the outer edges of the top sheet 226 are formed with recesses 226b, to serve as recesses in the outer edges of the central sheet 221 when joined thereto. These recesses are cooperable with projections in sheets 222-225 when the latter sheets are folded to an erect position to define the side walls 202-205 of article 200, as will be described more particularly below.
Base sheet 210 includes two further cardboard sheets 227, 228, adhesively joined to the inner surfaces of the outer sections of opposed sheets 224, 225 for strengthening purposes. Sheets 227, 228 may therefore also be of corrugated cardboard, but with the corrugations running perpendicularly to the corrugations in the outer sections of sheets 224, 225.
Base sheet 210 includes further strengthening strips 229 applied to the inner surfaces of the outer edges of the outer two opposed sheets 222, 223, for strengthening those edges. Strengthening strips 229 may therefore also be of corrugated cardboard, with the corrugations running perpendicularly to those in their respective sheets 222, 223.
The two sheets 222, 223, defining the two opposed side walls 202, 203 of the three-dimensional article 200, are of the same construction except for a slight modification in sheet 223 to provide the modular feature. Similarly, the two sheets 224, 225, defining the other opposed side walls of the three-dimensional article 200, are also of basically the same construction, except for a slight modification in sheet 224 to provide the modular feature.
As seen in
Sheet 222 defining side wall 202 is further formed with a hook formation 222f at each of the opposite ends of its outer section 222d. Sheet 222 is further formed with a flap 222g at each of the opposite ends of its inner section 222c. Flaps 222g are to be folded over the inner face of the inner section 222c of the respective sheet and adhesively joined thereto for strengthening purposes.
The opposed sheets 223 defining the opposite side wall 203 of article 200 is similarly constructed as described above with respect to sheet 222, except that it is formed with slots 223h-223j to provide the modular feature in article 200.
The two sheets 224, 225, defining the other pair of opposed side walls 204, 205 of article 200, are similarly constructed. Besides their adhesively coated inner sections (e.g., 224a) and mid-fold lines (e.g., 224b), the outer edges of the outer sections are similarly formed with projections (e.g., 224e) cooperable with recesses 226b in the bottom wall when sheets 224 and 225 are folded over to define the side wall 204 and 205 of the article.
The inner sections of the two sheets 224 and 225 are further formed with bendable flaps, e.g., 224f, at their opposite ends, but in this case one flap is formed with a recess, e.g., 224g, while the other is formed with a complimentary projection, e.g., 224h. As shown in
a-14d illustrate the sequence of folding operations for folding the base sheet into the three-dimensional article 200 illustrated in
It will be seen that the only operations required are folding operations, and that a high degree of dimensional stability and structural rigidity is effected by the engagement of projections 222e-225e into the recesses 226b in the bottom wall of the article, by the engagement of the hook projections corresponding to 222f into the recesses corresponding to 224g, and by the engagement of projections corresponding to 224h in the recesses 224f. It will also be seen that the all the interengaging projections are concealed by the folded over outer sections of each of the sheets 222-225; and that only fold lines, and no cut edges, are exposed for view. The so-produced three-dimensional article thereby presents an extremely pleasing appearance, which may be enhanced by coloring, or otherwise ornamenting, all surfaces exposed for view.
It will also be appreciated that the article produced, when including the cut-out 221a in the bottom wall 221, together with the other slots in the side walls cooperable therewith as described above, enables a plurality of such units to be assembled in modular fashion.
The invention has been described above with respect to several preferred embodiments for purposes of example only, it will be appreciated that many variations, modifications and other applications of the invention may be made. For example, while various surfaces are described as being joined by adhesive at the factory, such surfaces could be merely marked for joining with adhesive applied by the purchaser. Also, such surfaces could be merely coated with a moisture-responsive adhesive such that the purchaser would moisten the respective surfaces and effect the joining. In addition, other methods of joining could be used, for example buttons formed on one surface snappable into sockets formed in the other surface to be joined, or by mechanical “hook and loop” type fasteners (e.g. “Velcro”).
In addition, while the invention has been described with respect to using cardboard sheets, the invention could also be applied to other materials, such as thin plastic sheets. Further, while the invention has been described with respect to furniture articles, other types of articles could be assembled, such as receptacles, toys, etc.
Many other variations, modifications and applications of the invention will be apparent.
This application is related to U.S. application Ser. No. 11/______, concurrently filed with the instant application titled “Kits For Use In Forming Three-Dimensional Articles, Particularly Articles Of Furniture, From Flat Cardboard Sheets”, and assigned to the same assignee as the instant application.