Patent Application
20250194839
Embodiments of the present invention relate generally to a collapsible object having a closed three-dimensional shape.
Oversized ornaments are often used for holidays, parties, weddings, events, and other celebrations. For example, in wintertime snowmen, Christmas trees and ornaments, reindeer, and other decorations can be found. These objects can be large so they are visible in a home's yard or a retail location. While the size is advantageous for display, it can be a detriment when shipping and storing the objects in a retail store, warehouse, or homeowners' storage space.
U.S. Patent Pub. No. 2020/0273374 discloses an apparatus comprised of flexible gores that are serially connected to each other at their lateral adjoining edges. These gores have a hole in their polar region and a drawstring runs through the gores' holes such that, when the drawstring is pulled, the drawstring pulls the gores' polar regions together and a radial three dimensional shape forms.
U.S. Patent Pub. No. 2011/0095074 is directed toward a polygonal container having at least five interconnected body panels and a blank for making the polygonal container. The ends of the polygonal container are provided with a plurality of pie shaped triangular sections that can provide unique decorative experience to the user of a consumer product contained and dispensed from therein.
U.S. Pat. No. 3,571,958 discloses a pop up display that is constructed from two blanks and a closed loop resilient material. Each blank consists of a central polygonal panel to each edge of which is hingedly attached a pentagonal flap, which is further bounded by two inner sides flanking the side common to the flap and panel and two outer sides. At least one outer side of each flap may have a tab portion. The two blanks are placed with their panels in face to face contact and the closed loop is disposed about the periphery of the blanks so that it crosses each outer side and lies in contact with the exposed faces of the flaps. Under the influence of the closed loop of resilient material, the blanks are caused to adopt a polygonal configuration but can be flattened against the influence of the closed loop of resilient material for insertion into a flat container such as a mailing envelope or the like.
In a first embodiment, a collapsible faceted object comprises a plurality of interconnected rigid facet panels. The facet panels are arranged so that the object can be in either a flat configuration or an expanded configuration. In the flat configuration, the facet panels are substantially parallel to one another and the object has a first thickness in a direction perpendicular to the parallel facet panels. In the expanded configuration, the object has a visually continuous outer surface that forms a closed three-dimensional shape and a second thickness in the direction perpendicular. The second thickness is substantially larger than the first thickness. The object is capable of remaining in both the flat configuration and the expanded configuration without application of an external force.
In another embodiment, a collapsible faceted object comprises a plurality of pattern groups interconnected along a spine. Each pattern group includes a plurality of rigid facet panels so that each facet panel is attached to an adjacent facet in the respective pattern group by a flexible joint. Each facet panel is spaced from an adjacent facet panel by an open space when the object is in a collapsed state and each facet panel has an edge that is parallel to an edge of the adjacent facet panel when the object is in an expanded state. A guide mechanism is configured so that the object can be transformed from the collapsed state to the expanded state by simultaneously moving the facet panels to close the open spaces in a manner guided by the guide mechanism and so that the object can be transformed from the expanded state to the collapsed state by simultaneously moving the facet panels to create the open spaces between the facet panels in a manner guided by the guide mechanism.
Embodiments of making a collapsible object are also disclosed. In one embodiment, a plurality of separate pattern groups are formed from a hard-sided material. Each pattern group includes a plurality of facet panels separated by a flexible joint. Sliding alignment guide tabs are provided for the facet panels. The pattern groups are loaded into a fixture in a layered manner so that the sliding alignment guide tabs of one pattern group overlies an adjacent pattern group. Slot stiffener tabs are attached to the pattern groups so that each slot stiffener tab overlies but is not attached to the associated sliding alignment guide tabs thereby forming guide tab slot. Each pattern group is attached to an adjacent pattern group.
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
The following description provides examples of embodiments of the invention. It is understood that features shown in various embodiments can be combined.
In a first embodiment, a collapsible Christmas/holiday ornament resembles a traditional holiday tree ornament of a globe shaped sphere, teardrop or other 3-dimensional shape having a seemingly continuous unbroken exterior surface having interior volume made from 2-dimensional rigid sheet materials that can be disassembled or collapsed to a flattened state requiring reduced volumetric space (storage space). Such a “pop-up” design allows for ease and repeatable transformation from flat to expanded states without any excessive assembly or disassembly.
Using a combination of multi-sided shaped rigid facet panels, flexible hinged joints connecting adjacent facet panels, and retracting articulating or “sliding joints” that are allowed to open and close negative spaces in-between the facet panels in a mechanically controlled manner, a normally flat, rigid 2-dimensional sheet material can be manipulated to change its form from a 2-dimensional flat surface into a hard sided 3-dimensional shape resembling a known recognizable object having a visually unbroken surface. The mechanics of these interconnected, movable sliding articulating joints and facet surface panels afford minimal or no assembly effort or time to create the display object as well as enabling repeatable transformation from open to closed states.
As described below, the collapsible objects can take on a number of configurations. The holiday ornament is just one example.
These collapsible objects can be used in a number of contexts. In the commercial space, office buildings, municipal, hospitality, event centers, retail stores and malls can use the object or an assortment of objects for seasonal décor. Homeowner uses include smaller objects for interior décor and larger objects for outside, (e.g., on the lawn, hanging from balcony, eaves, or exterior tree).
The example Christmas ornament shown in
These sizes and uses are provided only as examples.
The example in
The surface can be opaque, translucent, or clear with printed artwork and/or have sparkles or other decorative surface materials with or without other added ornaments. Both opaque, translucent, and clear materials could have internal illumination and/or surface accent lighting (e.g., LED lighting) powered by batteries or cord to external power source.
Objects may include secondary accessory parts or other ornaments to enhance the design. Examples may include faux greenery, ribbons, a snowman's scarf or a gnome's staff.
While not shown in
In
The expansion process begins in
As shown in
As shown in
A more detailed illustration of the production of the sphere will be described with reference to
Components of the example cut-out patterns provided in
In this example, flat facet panel 1 is implemented as a multi-sided flat rigid surface panel. The shape of the facet panel 1 can be triangular, quadrilateral, pentagonal, hexagonal, octagonal, or other depending on the desired object shape upon expansion. The material might be a foldable sheet material such as cardstock, cardboard or plastic, or a rigid material such as sheet metal, plastic or wood-based sheet goods. Combinations or built-up laminations of these materials can also be used. For example, a paper surface sheet could be used with a plastic, composite or wood backing. Facet panels 1 incorporate various decorative surface treatments. A plurality of facet panels 1 can be combined to create pattern group 110-160, which can in turn be combined to create a sub-assembly (or a completed assembly).
For longevity or exterior uses plastic or composite, sheet metal, fiber-reinforced plastic (FRP) and/or other waterproof sheet goods can be used. Rigid sheet goods can be solid, honeycombed, corrugated, or laminated. The thickness and type of sheet good used is determined by the size, structural and aesthetic requirements of the object. Rigid materials are not required as the exterior surface. Soft materials such as fabric or vinyl may be substituted for rigid sheet goods if attached to a rigid framework (e.g., metal tubing, molded plastic, pipe, or rod) of the same outside shape of the intended flat facet panel 1 that may or may not include internal bracing. All other disclosed working mechanics are the same as hard sided objects. Soft sided objects may be preferable in some cases especially for larger objects.
A guide mechanism 10 controls the movement of expansion “opening” and contraction “closing” of the flat facet panels 1, articulating joints and negative open space in-between the flat facet panels 1 that allows a 2-dimensional sheet to be transformed with minimal effort into a 3-dimensional object. The guide mechanism 10 allows all the multiple, interconnected flat facet panels 1 to move in mass (expand or contract) at the same time in a coordinated, controlled singular movement. In this example, the guide mechanism 10 is implemented using a sliding alignment guide tab.
The sliding alignment guide tab 10 can be formed integrally with the facet panel 1 as shown in
The sliding alignment guide tab 10 is captured by the guide tab slot 18 to ensure proper alignment of the flat facet panels 1 perimeter edges in the “expanded” state thereby achieving a visually seamless, unbroken surface. The material of the sliding alignment guide tab 10 may be the same as the flat facet panels 1, or a different material or method (e.g., guide rods, wires, cords) as long as material and/or method performs the controlled guiding and alignment of the flat facet panel 1 as intended.
Pattern connection tab 12 can connect patterns via a flexible joint (e.g., a) allowing a hinging motion. This element can be permanent (e.g., overlapping tab with glue, tape (e.g., double sided), flap hinge, piano hinge) and/or temporary (e.g., slot and locking tab, loose pin, hook and loop, drawstring, clasp, strap and buckle, strap and eyelet, roto-lock, magnet). Other means of connection are also possible to connect multiple pattern cutouts to one another.
Pattern group connection tab 13 is similar to pattern connection tab 12. This connection tab 13 can connect a pattern to itself to create a “ring” or other shape while allowing a hinging motion (e.g., a). This can be permanent glue and/or temporary slot and locking tab. Again, other means of connection are also possible. In some examples, the group connection tab 13 can connect the associated facet panel to a further facet panel, which can be helpful in the fabrication of larger objects.
Slot stiffener tab 14 can provide material for construction of and to hold the guide tabs slot 18. The slot stiffener tab 14 is a surface for controlling the sliding movement of guide tab 10 as well as providing a landing surface for adjacent facet panels 1, aligning the panel edges to be flush and parallel to each other over the entire length of the edge. As discussed above, in operation, sliding alignment guide tab 10 is inserted into guide tab slot 18 and is free to slide within the guide tab slot 18 over its length of travel. Guide tab slot 18 controls direction, alignment, and end limits of movement of sliding alignment guide tab 10.
Sliding alignment guide tab extraction limit lock 119 limits travel of, captures, and prevents sliding alignment guide tab 10 from inadvertently coming out of guide tab slot 18. Extraction limit locks 119 may be used on other guide tabs 10 as needed. Sliding alignment guide tab extraction limit lock 119 shown is but one example of a variety of designs that may be used that perform the same function.
The reference a indicates a movable fold line, hinged joint or otherwise flexible connection between flat facet panels 1, connection tabs 12, 13 or other parts requiring a flexible joint in-between. This can be a score line, crease and fold, with or without perforations to assist bending, live hinge of flexible material, mechanical hinge, “V” groove of rigid material having a flexible face material, or a built-up lamination of a flexible face material glued to a subterranean rigid material, or other hingedly mechanism allowing a rotating movement between parts. Connection a may be a temporary or permanent connection.
Also illustrated are an s angle, which is the final open angle at bottom and top of opened sphere and a t angle, which is the bottom angle of the cone pattern in the flattened 2-dimensional state. A limit edge i can be used to stop the opening of the lower (and upper) cone shapes at the correct angle. Opposing downward force on each side of cone interior (left and right) maintains correct angle of cone shape under compression of sphere in the opened state.
As discussed above, the object can resemble a recognizable object. The snowflake 19 is included to illustrate an example of implementing this feature. For example, a Christmas ornament could be implemented with snowflake designs over a colored surface. In general, any surface artwork, glitter, sequence, printed or applied graphics, jewels, ornaments, or designs can be implemented. The visual appearance is limited only by the imagination of the maker.
The collection of facet panels 1 can be combined to create a connected pattern group, six of which are shown in this example. In this example, the connected pattern groups 110-160 forms the top (or bottom) half sphere sub-assembly 100. While a sphere can be formed with two sub-assemblies 100 more complicated shapes could require more sub-assemblies, the number being limited only by practical concerns.
Top mid ring facet group 120 is designed to allow the object to lie substantially flat in closed state and to be a cone-shaped 3-dimensional ring in opened state. Two facet groups 120 can be joined together via pattern group connection tabs 13 create a completed ring. Top center facet group 130, bottom center facet group 140, and bottom mid-ring facet group 150 are similar in design and function as top mid ring facet group 120.
As previously stated, it is understood that while this discussion focuses on one specific embodiment other materials, shapes, connectors, fabrication and assembly techniques, and relative dimensions are possible.
In the example provided in
For a small object, many facet panels 1, sliding alignment guide tabs 10, slot stiffener tabs 14, pattern connection tabs 13, and other parts can be joined together and cut from one blank or sheet of material in a common pattern or patterns. A score line, crease fold or V groove on a single material or built-up lamination of flexible surface materials backed up by rigid materials or other means of bending may be used to create a flexible fold line in-between various parts at location a.
With a larger object, it could be more efficient if only one part is made from one sheet of goods or multiple sheets and all other parts are connected to one another at location a via a mechanical hinge, live hinge, or another applied hinging device used to connect the various parts hingedly allowing a bending hinging motion between them. These can be temporary (e.g., loose pin hinge, hook and loop, magnets) or permanent connections between connecting the parts together. In an even larger part, a single part may be manufactured from multiple other framing and sheet materials (e.g., steel tube, sheet metal, sheet FRP, plastic molded or otherwise).
In this example, the sliding alignment guide tabs 10 (and/or slot stiffener tabs 14 could be included) would be separate cut-out parts and affixed to the flat facet panels 1 via glue tabs 11 or other means of attachment (e.g., live hinge, mechanical hinge). Glue tab landing locations on the center spine plate 15 are shown. The actual pattern shapes, order and combination of part assembly and attachment method to one another during manufacturing may be adjusted or changed per specific manufacturing requirements of size, shape, materials, manufacturing means and methods or other parameters and/or end use requirements. Inter-woven parts may be woven through by hand or machine to achieve a “woven” functionality of parts.
Prior to placing parts mask 349 in fixture 347, glue is applied to the glue tabs 14a, and on the center spine plate 15 on either side of the bendable line a (glue shown by glue dots, hidden hashed circle and bars). Parts mask 349 is placed in fixture 347, on top of the pre-loaded ring groups 123, 120, 130, 140, 156 with the glue facing downward toward the ring parts already in the fixture.
The two alternative sub-assemblies shown in
In
On each pattern group (e.g., ring), all the facet panels 1 that are connected to the center panel c-c (i.e., spine), following in turn, are forced to expand outward or “open” from flat rings to round rings, thus forming a round 3-dimensional sphere. As the rings expand outwards, the open space in-between the rings begin to close. This closing movement of the open spaces between the rings force the sliding alignment guide tabs 10 to slide into the guide tab slots 18. This interaction of the sliding alignment guide tabs 10 to slide into the guide tab slots 18 control the movement, direction of travel, travel path, length of travel and maintains the proper alignment of the facet panels 1 edges, keeping them parallel with one another when closed.
In
In this example, the top cone 460 is the same as the bottom cone but with no actuator cords 60 attached. The top cone 460 uses the pushing down motion from the hand, instead of the actuator cords 60 to perpetuate the opening motion needed to rotate the actuator control plates 115 inwards and force open the facet panels 1 of the top cone and stopping at the correct spot due to the limiting stop/brake of angle i on the actuator control plates 115. Angle i limits the travel/opening of the cone and resists any implied over-compression or collapsing force of the sphere, helping to maintain its shape under compression stresses.
As an alternative, the actuator tab 115 may not be used. A simple cone can be made with facet panels 1 being joined to one another to create a cone shape. In this case, the cones still function as intended, folding from flat 2-dimensional to a 3-dimensional cone shape (movement h) provided the facet panel 1 number is such to make a symmetrical folding and flattening possible. The simple cones may still initiate the sphere opening and closing but without the added stability and internal support the actuator tabs 115 provides.
An alternate method to perform movement g, to open the object, is to do so manually, that is, instead of pulling the actuator cord 60 to initiate movement g (
To provide one example,
In
Examining upper section 570, the two pattern group connection tabs 13, one on each side of the part, are folded over 180 degrees toward what will later be the inside of the object. Next the entire part is folded over 180 degrees (i.e., in half) along center fold line r. The two pattern group connection tabs 13 are now facing one another (i.e., on top of one another) are glued together creating a continuous cone. Collar flap 29 is wrapped in the interior creating a circular ring to reinforce the opening where the actuator cord 60 passes through. Other means of reinforcing the hole where the cord passes through are possible (e.g., plastic collar).
Examining lower section 571, the two inner pattern group connection tabs 13a are shown. Glue is applied to the tabs, which are folded over 180 degrees along fold line r, with the outer surfaces on the inside facing one another. Gluing the tabs 13a together creates a ridged spine. As with the upper section, the two outer connection tabs 13, one on each side of the part, are folded over 180 degrees along the fold line, toward what will later be the inside of the object.
At this time both sides of facet panels 571 are folded 360 degrees at fold line u, back on themselves thereby creating a cone shape and placing the finished exterior surfaces on the outside and both left and right glue tabs 13, 13a on the inside of the object. Pattern group connection tabs 13, now facing one another are glued together creating a continuous flattened cone. During this process the two remaining sliding alignment guide tabs 10 are placed in front of slot stiffener tabs 14 and are inserted into guide tab slots 18.
Movement w is shown whereby the actuator cord 60 is pulled up with one hand. The other hand holds the upper cone 570 in place and/or pushes it down. Pulling on the actuator cord 60 combined with the resistance on the upper cone 570 transmits the force downwards through the center facet panels 1 at c-c on both sides of the object and also at the same time pulls the lower glue tab spines 13, 13a upwards and inwards. This in tern forces the upper and lower cones (570, 571) toward one another, in compression. These combined forces cause the center facet panels at c-c to push outwards, expanding the cone and also causing the sliding alignment guide tabs 10 to rotate downwards and slide into the guide tab slots 18 until the upper and lower cones meet creating a proper hexagon with a closed, visually unbroken surface. Cord lock 499 is added to keep the entire object in tension (i.e., in the expanded state).
An alternate method to perform movement w is to push the object poles together, by hand, opening the object, and then pulling taught and locking the actuator cord 60 to maintain tension to keep the object in the fully expanded state. As noted above, the actuator cord 60 can be replaced (or supplemented) with another device that performs the same function.
The object is closed (i.e., returned to the flat 2-dimensional shape) by releasing cord lock 499 allowing freedom of movement of actuator cord 60 and pressing with the hands on both sides of the object at the equator in the location of longitudinal center line (i.e., spine) facet panels 1 at c-c, reversing the opening movement, until the object is in its fully flattened state.
Although different in some aspects and details, movement w is substantially similar in principle to the mechanics of parts and movements outlined in the sphere example and embodies the design ideas presented herein.
While holding the object in place, pulling the actuator cord 60 upwards causes the actuator control plate 115 center upwards extending the plate arms thus pushing the facet panels 1 at c-c outwards, opening the object. Similar to the candy cane actuator plate, this plate is slightly longer than the cross section of the opened hexagon, thus wedging it in position in the fully open state and preventing it from being pulled past 180 degrees thereby inverting it, rendering it ineffective. Cord lock 499 keeps the object in tension preventing inadvertent collapsing.
The object is collapsed by releasing cord lock 499 and pressing on facet panels 1 at location c-c at the object equator.
The example provided in
As another example, a greeting card can be presented in the form of a collapsible object. The card could be paired with an envelope of a suitable size. As but one example, a picture can be taken of the family and printed on the facet panels of the card. With the pull of a string the family will present in three dimensions.
The provisional application (63/239,179) includes photographs (in
The formation occurs once, for example, at the factory where the object is fabricated. The object can be flattened and shipped to the user in one or more pieces. In the Christmas ornament example above, the final ornament can be delivered as a single piece or in two pieces if the neck is separated from the sphere or many parts for a more DIY home assembly project. Other larger or more complex structures can be shipped in multiple pieces, assembled and expanded by the end user.
In
The actuator plate 530 is designed in such a manner that its measured length along fold line a (x axis of part) is the same diameter as the inside of the opened cylinder diameter, enabling it to slide inside the cylinder walls freely. The perpendicular measurement (y axis) of the actuator plate 530 (glue tab 12 to glue tab 12 dimension) is slightly larger than the inside diameter of the fully opened cylinder diameter. The elongated dimension of the actuator plate 530 in the y axis acts as a “stopper” similar to a cork in a bottle opening. As the actuator cord 60 is pulled, the plates fold outwards opening the cylinder tube. Continuing to open, as soon as a perfectly shaped symmetrical decagon is formed, created and maintained by the correct x axis dimension of the actuator plate 530, all the interior cylinder tube walls (flat facet panels 1) lock tight against the outside edges of the actuator plate 530 edges. Because of the closed circular nature of a tube, the tube cannot move any higher in height (y axis) or in any direction, thus locking all the parts in place and maintaining a 3-dimensional decagon shape.
The limiting dimension in the height (y axis) keeps the actuator plates 530 at an acute angle, not fully opened and wedged in place seating the plate edges like a cork against the interior cylinder walls. This design prevents the actuator plates 530 from being pulled through, past 180 degrees, reversing or inverting it, thus allowing it to collapse in the opposite direction and rendering it ineffective.
In
As the shape of connected facet panels 1 may vary in more complex objects, the connected panels at spine c-c may take on an irregular pathway (i.e., not straight).
As with the sphere, the number of surface facet panels 1 may vary to any number. As an example, a large four foot diameter candy cane can have 26 facet panels 1 along its circumference. Using the formula provided, there would be six facet panels, one on each side of a center (spine) panel, thus 13 facet panels per side when collapsed. Any number of cylinder wall or sphere facet panels 1 may be used as long as the number is coordinated with the opening/closing mechanism to allow the object to fully open as intended and close to a substantially flattened condition at will.
In this state shown in
Shown on top curve 512 and straight shaft 522 is a stopper knot located on one end 117 of the actuator cords 60 and held tight by a cord locking device 118 on the other end, maintaining tension and preventing loosening of the actuator cord 60 and thus, holding the opened object in tension, preventing the collapsing of the object until desired.
Depending on the size, very large, 12′ or more as an example, the top curve 512 and straight shaft 522 parts may be further divided into smaller sections for later assembly.
In this example the candy cane utilizes the mechanics of retracting panels z to control the opening and closing of open spaces in-between rigid facet panels 1 to manipulate an object's shape to appear to have a seamless, unbroken continuous surface. The sphere example utilized sliding guide tabs 10, guide tab slots 18, and slot stiffener tabs 14 to achieve substantially the same mechanical effect and result. Both systems as well as a variety of others not described herein may be implemented alone or in concert, to achieve the same mechanical effect, allowing the opening and closing of open spaces in a coordinated movement to obtain a desired shape of a closed unbroken surface appearance with minimal assembly.
For all embodiments, a plastic sheet, sheet metal, or FRP sheet can be used for the exterior flat facet panels surfaces 1. As another example,
For all embodiments, perhaps depending on the size of the object, other material, activation mechanisms and devices may be used instead of, or in combination with, the actuator pull cord 60 and sliding alignment guide tabs 10, guide tab slots 18, slot stiffener tabs 14, actuator control plates 115 or 530 to affect the opening and closing of the object. A multitude of different design details and materials may be used to achieve the same opening and closing effect. Alternate means may include but not be limited to cardboard or plastic push rods for smaller greeting card sizes. Wood, plastic, metal rod or tube or cords or wires could be used for a system of hinged actuator arms and levers or captured sliding cords or wires in place of the flat actuator tab to open and close the sphere or tube walls for larger sizes.
In various embodiments, the pull cord 60 can be implemented using different materials selected based on factors such as object size, expected load, desired durability, and operating environment. For interior decorative objects, a braided nylon or polyester cord provides good flexibility while maintaining tensile strength. In an embodiment requiring higher strength, such as for larger objects exceeding 24 inches in diameter, metal cables like stainless steel or galvanized wire rope can be utilized. In another embodiment intended for exterior use, UV-resistant materials such as Spectra® fiber or aramid cords provide enhanced weatherability. In an embodiment requiring minimal stretch, composite fiber cords incorporating carbon fiber or Kevlar® strands maintain dimensional stability under load. The cord diameter can be sized according to the expected tensile forces, with smaller objects using cords around 1-2 mm in diameter while larger implementations may use cords up to 6 mm or more in diameter. In one or more embodiments, the cord ends can be finished with crimped metal ferrules, heat-shrink caps, or knotted stoppers to prevent fraying and ensure secure attachment to the connection points.
In various embodiments, different cord lock mechanisms 499 can be implemented to maintain tension and secure the object 300 in its expanded state. A spring-loaded cam lock provides reliable operation by using an internal cam that automatically grips the cord 60 when tension is applied and releases when a release lever is actuated. In an embodiment using a friction lock, the cord 60 passes through a tapered channel where a sliding wedge element creates increasing friction as tension increases. For larger objects requiring higher holding forces, a jam cleat configuration incorporates angled grooves that bite into the cord with increasing security under load. In another embodiment, a toggle-style cord lock 499 uses an internal pivoting bar that creates a sharp bend in the cord path when engaged. A ratcheting cord lock 499 can be implemented in embodiments requiring precise tension adjustment, allowing incremental tightening while preventing unwanted loosening. In an embodiment designed for quick release, a push-button cord lock enables rapid cord adjustment while maintaining secure holding force when engaged. The cord lock housing can be formed from durable materials such as reinforced plastic or metal alloys to withstand repeated use.
As an example,
As discussed above, the pull cord 60 extends outside the object 300 for use in expanding the object from the collapsed state to the expanded state. In this embodiment, a pulley 61 is used in conjunction with the cord 60 and cord lock 499 to hold the uppermost ring 110 against the adjacent ring 120. This embodiment is useful to avoid a gap between the uppermost rings 110 and 120.
As shown in
In various embodiments, attachment points 65 for securing the pull cord 60 to the object 300 can be implemented using different configurations to ensure reliable operation and structural integrity. Metal grommets can be installed through the facet panels (e.g., 110) to provide reinforced cord attachment points 65 while distributing loads across the panel material. In an embodiment using higher strength materials, riveted brackets formed from aluminum or stainless steel create secure mounting points that resist pull-out under tension. For applications requiring frequent cord replacement or adjustment, quick-connect clips or carabiners enable tool-free cord installation while maintaining secure attachment.
In another embodiment, molded plastic reinforcement bosses can be bonded or heat-welded to the facet panels, incorporating integral cord channels and attachment features. The attachment points 65 can include rounded edges or roller surfaces where the cord changes direction to prevent abrasion and wear. In an embodiment designed for larger objects, metal backing plates can be implemented on both sides of the facet panel to distribute loads over a wider area. For applications requiring weather resistance, sealed bushings or waterproof cord guides can be installed at the attachment points to prevent moisture ingress. In one or more embodiments, the attachment points 65 can incorporate swivel features to prevent cord twisting as the object moves between collapsed and expanded states.
The pull cord 60 exits the object 300 through a singular location (e.g., a hole) located at the top of the object and passes through an external cord lock 499. The actuator pull cord 60 is held by the cord lock 499 to be taut and under tension when the object 300 is in the expanded position. In this position, the cord lock 499 is pushed against the top of the object 300 so that the engaged and locked cord lock 499 exerts a downward force upon the top of the object 300. This downward force is countered by the upward pulling force of the pull cord 60 attached to the bottom of the object. This tension between the upper and lower sections keeps the entire object 300 in constant compression, maintaining the open state of the object without any force external to the object (i.e., not part of the object).
The system incorporating the pull cord 60 and the introduction of pulley 61 works by using redirected tension forces to pull the upper and lower halves of the object together in a straighter line, directly opposing, evenly distributed manner, as well as over a wider area, thus being more effective at holding the object under equalized tension.
In various embodiments, pulleys 61 can be implemented using different materials and bearing configurations selected to optimize performance and durability. For smaller decorative objects 300, injection-molded plastic pulleys incorporating acetal or nylon materials provide smooth operation with minimal friction. In an embodiment designed for heavier loads, machined aluminum or stainless steel pulleys 60 offer enhanced strength and wear resistance. Ball bearing pulleys can be implemented to minimize rotational friction and provide smoother cord movement, particularly beneficial in larger objects where higher tensile forces are present. In another embodiment, plain bearing pulleys using self-lubricating materials like oil-impregnated bronze provide reliable operation with reduced complexity. For applications requiring corrosion resistance, such as seasonal outdoor displays, marine-grade pulleys incorporating sealed bearings and non-corroding materials can be utilized.
The pulley wheel diameter can be sized according to the cord diameter and expected loads, with smaller implementations using wheels around 15-25 mm in diameter while larger objects may incorporate wheels up to 50 mm or more. In one or more embodiments, the pulley mounting can include integral reinforcement ribs and attachment points designed to distribute loads across the facet panel surface. In an embodiment requiring low friction with minimal maintenance, ceramic bearing pulleys provide excellent wear resistance and smooth operation without lubrication. For the cord 60, a monofilament line offers low friction and resistance to kinking in embodiments with tight routing paths through the pulley system.
In
As shown in
A tension to the end of the actuator cord 60 accessible from the outside to transform the collapsible object 300 from a collapsed state to an expanded state. The cord lock 499 is operably coupled to the actuator cord 60 to maintain the collapsible object 300 in the expanded state. The cord lock 499 can be engaged by pressing the cord lock 499 against an exterior surface of one of the facet panels 110 to create opposing forces between the cord lock 499 and the actuator cord 60. To collapse the object 300, the cord lock 499 can be released to remove tension from the actuator cord 60. The collapsible object 300 can then be transformed from the expanded state to the collapsed state by applying inward pressure, e.g., from outside the object, to opposing sides of the collapsible object 300.
As shown in
For example, a motorized actuator system can be implemented to provide automated expansion and collapse of the object 300. A compact electric motor, such as a DC gear motor or stepper motor, can be mounted within the object's base or integrated into the structure. In an embodiment using a worm gear drive system, the motor's rotational motion is converted to linear movement while providing self-locking capability in the expanded position. The drive system can incorporate limit switches or position sensors to automatically stop actuation at the fully expanded and collapsed positions. In another embodiment, a rack and pinion mechanism driven by the motor provides controlled linear movement while maintaining precise position control. The motorized system can include a manual override feature, such as a hand crank or release mechanism, to enable operation during power loss. In one or more embodiments, multiple synchronized motors can be distributed around the object's circumference to provide balanced actuation forces.
A microcontroller can be implemented to manage motor speed, position feedback, and soft start/stop functionality to prevent sudden movements. The system can include thermal protection and current limiting features to prevent motor damage during extended operation. In an embodiment designed for remote operation, wireless control capabilities enable expansion and collapse using a smartphone app or remote control device. The motor and drive components can be enclosed in weatherproof housing for outdoor applications requiring protection from environmental conditions.
Two pull cord/pulley systems are shown in
In various embodiments, a distributed pulley system can be implemented using multiple smaller pulleys 61 arranged throughout each section of the object. Rather than relying on a single large pulley per section, an array of compact pulleys can be positioned along the facet panel edges to provide more uniform force distribution. For example, sets of two to six pulleys per section can work in concert to guide the cord path while reducing local stress concentrations. The distributed configuration can enable smoother movement between states by maintaining more consistent tension across the panel surfaces. The pulleys 61 can be arranged in opposing pairs to create a block-and-tackle effect, providing mechanical advantage to reduce the required actuation force. The smaller pulleys can be positioned to optimize cord routing geometry while maintaining low friction operation through the multiple direction changes.
When multiple cords 60 are used, the cord lock 499 can incorporate multiple channels to accommodate separate cords while maintaining independent tension control for each cord. If multiple cord/pulley systems 60/61 are utilized it may be convenient to use a separate cord for each or each pair of systems. These cords 60 can attached, e.g., internally with respect to the object, to another element that extends outside. This other element can be another cord or rigid (or semi-rigid) element such as a rod, bar, pole, stick, or dowel. In fact, the other element can be used even if a single cord 60 is provided internally.
Alternately, multiple internal cords may attach to a single central, or multiple junction plates to reduce the number of cords leaving the object. For example, a junction plate can be implemented with a rigid connector, typically made of metal or high-strength composite material, designed to link multiple ropes or cables together so they can be pulled or tensioned using a single rope or cable. The element distributes the load evenly among the attached lines, preventing tangling and ensuring efficient force transfer. Junction plates can be used in embodiments where the synchronized pulling of multiple cables is desirable.
In various embodiments, rigid or semi-rigid push/pull rods can be implemented as an alternative to flexible cords 60 for actuating the object between collapsed and expanded states. The rods can be formed from materials such as aluminum tubing, carbon fiber composites, or engineered polymers to provide controlled movement while maintaining dimensional stability. In an embodiment utilizing telescoping rods, nested sections extend and retract in a controlled manner to facilitate smooth transition between states. The rods can be coupled to the facet panels using pivoting joints or ball-and-socket connections to accommodate angular changes during movement.
In another embodiment, semi-rigid polymer rods provide sufficient flexibility to bend during actuation while maintaining enough rigidity to transmit pushing and pulling forces. Guide channels can be incorporated along the facet panels to maintain rod alignment and prevent buckling during compression. In one or more embodiments, the rods can include integrated locking features that automatically engage when the object reaches the fully expanded state. For larger implementations, hydraulic or pneumatic cylinders can be utilized in place of mechanical rods to provide controlled actuation with increased force multiplication. The rod ends can incorporate threaded adjusters or turnbuckles to enable fine-tuning of the expanded geometry and tension settings.
As discussed above, the system may use multiple pulleys (e.g., block and tackle) to provide a mechanical advantage, reducing the force needed to pull the object together. An example of this is a double pulley system whereas one pulley 61 is attached to one location of the object and another pulley 61 is attached to an opposing location. The pull cord 60 then loops through both pulleys. When the cord is pulled, both pulley attachment points as well as the cord end all move toward each other simultaneously.
The object 300 is transformed from the collapsed to the expanded state by applying force to bring the object 300 into a compressive state or under tension. This result can be achieved using various mechanisms, including tensioning forces and/or mechanical linkages. Lever systems alone or in concert with pulley systems may be used to exert a pulling force on two opposing sides of the objects to bring them closer together and in tension.
Pulleys 61 may be substituted with any low friction device that changes and redirects the pulling force of the pull cord 60 and/or provides a mechanical advantage reducing the needed force to manipulate the object. For example, the redirection of the force can be achieved using a hole, grommet, eye, wire loop, or pipe.
In this embodiment, the internal pull cord and pulley system comprises a set of cords 60 routed through a series of low-friction pulleys 61, or other means of redirecting the cord, anchored to the inner frame of the collapsible object. When a user applies tension to a primary external control cord, the internal pulley system directs force evenly across multiple opposing points. Then action draws the object sides inward, toward one another, in a controlled manor, placing the entire object in tension thus keeping the object in an open state.
In summary, a collapsible object is disclosed herein. A plurality of interconnected facet panels are formed from a rigid or hard-sided material or rigid frame with soft (or hard) material surface material. The facet panels are arranged so that the object can be in either a flat state or an expanded state.
In the flat state, the facet panels are substantially parallel to one another. The object has a first thickness in a direction perpendicular to the substantially parallel facet panels when in the flat state. This first thickness is close to, generally not greater than five times, the sum of thicknesses of the substantially parallel facet panels in the direction perpendicular to the parallel facet panels but can be more or less in thickness depending on variety of materials and fabrication details used.
In the expanded state, the object has a visually continuous outer surface that forms a closed three-dimensional shape. The object has a second thickness in the direction perpendicular to the parallel facet panels when in the expanded state. The second thickness is relatively large, possibly ten or thirty or hundreds of times larger than the first thickness but may vary more or less due to numerous factors both aesthetic (e.g., the final intended design shape) and/or functional (e.g., material thickness).
For smaller objects, the first thickness can be less than about one inch, e.g., a quarter of an inch while the second thickness is six inches or more. Larger objects typically include heavier materials and as such would have larger thicknesses. For example, the first thickness can be between three inches and six inches and the second thickness can be 24 inches or more. Once again, these thicknesses are merely provided as examples.
The facet panels can include fixed facet panels arranged in a first direction and sliding facet panels arranged in a second direction different than the first direction. The position of the sliding facet panels is different relative to the fixed facet panels in the flat state compared to the expanded position.
In the examples shown above, the temporary and repeatable transformation between a rigid 2-dimensional sheet material into a rigid 3-dimensional shape of the same material is possible by the specific geometry of the flat facet panel shapes 1, the specific geometry of cut out open negative spaces created between the surface flat facet panel shapes 1, and the articulating mechanisms utilized (e.g., sliding tabs or retracting panels) to control and keep aligned the opening and closing movement of the surface facet panels in a repeatable, predictable and desirable way.
Linkages within the object and/or an “activation device” is incorporated to move some, all or a combination of parts in one or a series of movements to “open” or “close” the object, initiated by the user with minimal time or effort.
In one example, the first thickness is substantially equal to the sum of thicknesses of the substantially parallel facet panels in the direction perpendicular to the parallel facet panels.
The second thickness can be greater than six inches. In another example, the second thickness can be four feet or more. A large setting could utilize collapsible ornaments of twelve feet or more.
The object can present in many forms in the expanded state, including a recognizable object. For example, design disposed on the outer surface of the object so that the object resembles the recognizable object. As examples, the object can resemble a Holiday/Christmas ornament, special events décor, athletic ball or an animal in the expanded state.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description.
This application is a continuation-in-part of U.S. patent application Ser. No. 17/899,850, filed Aug. 31, 2022, which claims the benefit of U.S. Provisional Application No. 63/239,179, filed on Aug. 31, 2021, which applications are hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63239179 | Aug 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17899850 | Aug 2022 | US |
| Child | 19063534 | US |
