RELATED APPLICATIONThis 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.
FIELD AND BACKGROUND OF THE INVENTIONThe 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.
OBJECTS AND BRIEF SUMMARY OF THE PRESENT INVENTIONAn 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.
BRIEF DESCRIPTION OF THE DRAWINGSThe invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 illustrates one form of three-dimensional article, such as an open cabinet, partitioned container or the like, that may be formed from a flat base sheet or kit constructed in accordance with the present invention;
FIG. 2 illustrates a kit including the basic components, in flat sheet form as supplied by the factory and as to be used by the user, for assembling the three-dimensional article ofFIG. 1;
FIG. 3 more particularly illustrates the various sheets, in flat form, used in making the components of the kit inFIG. 2;
FIG. 4 illustrates the partition sheets in folded form in the kit ofFIG. 2;
FIG. 5 is a top plan view illustrating the base sheet in the kit ofFIG. 2;
FIG. 6 is a bottom plan view of the base sheet in the kit ofFIG. 2;
FIG. 7 illustrates the components of the kit ofFIG. 2 in an intermediate stage of assembly of the three-dimensional article;
FIGS. 8a-8iillustrate the sequential steps used in forming, from the components of the kit ofFIG. 2, the three-dimensional article ofFIG. 1;
FIG. 9 illustrates another three-dimensional article which may be formed from a flat base sheet constructed in accordance with the present invention;
FIG. 10 illustrates the base sheet in flat form, as produced by the factory and as to be used by the user, for producing the three-dimensional article illustrated inFIG. 9;
FIG. 11 illustrates, in flat form, the various sheet components used in making the base sheet ofFIG. 10;
FIGS. 12 and 13 illustrate top and bottom faces of the base sheet ofFIG. 10;
FIGS. 14a-14dillustrate the sequence of operations involved in using the base sheet ofFIG. 10 for forming the article ofFIG. 9;
FIGS. 15a,15band15cillustrate how the article ofFIG. 9 can be constructed to serve as a modular unit for assembling various configurations of shelving, bookcases, and the like;
FIGS. 16a,16b.,17a,17band18a,18billustrate other variations in the modular units ofFIGS. 15aand15b;
FIG. 19 illustrates a further variation in the modular unit;
andFIGS. 20 and 21 illustrate examples of various configurations of shelving, bookcases, and the like that can be assembled with the modular units ofFIGS. 9-21.
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.
DESCRIPTION OF PREFERRED EMBODIMENTSAs 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.
The Embodiment of FIGS.1-8iFIGS. 1-8iillustrate 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 inFIG. 1. The two basic components of the kit are illustrated in flat form inFIG. 2.FIGS. 3-6 illustrate the construction of these basic components; andFIGS. 7, and8a-8iillustrate the manner of using those components for producing the article ofFIG. 1.
The three-dimensional article illustrated inFIG. 1, therein generally designated100, is a cabinet, partitioned receptacle or the like, of rectangular configuration. It includes fourside walls101,102,103,104; abottom wall105; a plurality oftransverse partitions106 of one construction, andend partitions107 of a slightly different construction; and alongitudinal partition108.
FIG. 2 illustrates the contents of the kit, in flat form as supplied to the user from the factory, which may be used for assembling the three-dimensional article ofFIG. 1. Thus, as shown inFIG. 2, such a kit includes abase sheet110 cut according to a predetermined configuration and formed with a predetermined arrangement of fold lines as will be described more particularly below. The kit also includes a plurality ofpartitions106 and107 also supplied in flat form.FIG. 3 more particularly illustrates the contents of the kit in flat sheet form as initially produced at the factory, whereasFIGS. 4-6 illustrate these components in the folded form and adhesively joined form as supplied by the factory to the purchaser.
As shown inFIG. 3, each of thetransverse partitions106 and107 is made of a flat corrugated cardboard sheet of the configuration illustrated, each formed with afold line106a,107a,extending midway for its full length to divide the respective sheet into two sections on opposite sides of the fold line. One section is coated with an adhesive, as shown (by dotted lines) at106b,107b,to enable it to be folded against, and adhesively joined to, the other section. In the case of the endtransverse partitions107, the adhesively-coated section of the partition is of slightly shorter length than the other section, so as to produce a singlebendable flap107cin each of these partitions. In the case of the middletransverse partitions106, the two sections are of equal length, but the adhesive coating on one section is applied only to the central section of the respective partition, leaving both opposite end portions uncoated, so that in the folded condition of these partitions, twosuch flaps106care formed at the non-adhesively-joined ends of the partition.
As further seen inFIG. 3, the flap at one end of each partition is formed with a projection, as shown at106d,107d,whereas the opposite end of the respective partition is formed with a recess, as shown at106e,107e.As will be described more particularly below and as shown particularly inFIG. 7, the flaps at the ends of these partitions, with the ribs and recesses of adjacent partitions interengaging, are used for mounting the partitions within the article in a manner to provide dimensional rigidity, structural stability, and a very pleasing appearance.
Each partition is further formed with a slot,106f,107f,for accommodating thelongitudinal partition108.
The longitudinal partition108 (FIG. 1) is not defined by a separate cardboard sheet, but rather is integrally constructed with thebottom wall105 ofbase sheet110, as will be described more particularly below.
The construction of thebase sheet110 is also illustrated inFIG. 3. It is constructed of a plurality of flat cardboard sheets111-118 each cut as shown inFIG. 3. Each is formed with slots as shown in full lines inFIG. 3, and is coated with adhesive surfaces as shown in dotted lines inFIG. 3. The arrangement is such that they can all be joined at their adhesively-coated surfaces to produce thebase sheet110 ofFIG. 2 to be used to produce the three-dimensional article100 ofFIG. 1. The joining of the sheets111-118 would in most cases be performed by adhesive at the factory to produce thebase sheet110 to be supplied to the purchaser, but it is contemplated that, in some cases, the actual joining of the various sheets could be done by the purchaser by using an adhesive, or mechanical-type connectors, as will be described below.
Cardboard sheet111 is of rectangular configuration and serves as thebottom wall105 ofarticle100. Sheets112-115 are adhesively joined at theirinner edges112a-115a,to the under surface ofsheet111. They are formed withfold lines112b-115b,to permit these sheets to be bent upwardly to an erect condition with respect to the bottom sheet. Each of the sheets112-115 is formed with a further fold line, e.g.,112cmidway 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 twocardboard sheets112,113 which, as indicated earlier, constitute thelongitudinal sides102 and103 ofarticle100, are formed, in their outer sections, with three equally-spaced slots, e.g.,112f,for accommodating the three intermediatetransverse partitions107; whereas the outer sections ofsheets114,115, which define the transverse side walls ofarticle100, are provided with a single middle slot, e.g.,114f,to accommodate thelongitudinal partition108.
As further seen inFIG. 3, the outer edges of the twosheets112,113, defining thelongitudinal side walls102,103 of the assembledarticle100, are formed with projections, e.g.,112g,one between each pair of slots formed in the outer section of the respective sheet. As will be described below, these projections are engageable with recesses formed in thebottom wall105 of the three-dimensional article to firmly secure the side walls in erect condition.
In addition, the inner section of eachsheet112,113, 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 bysheets114,115) to more firmly secure all the side walls in an erect position in the three-dimensional condition ofarticle100.
The twosheets114,115 defining thetransverse side walls104,105 ofarticle100, are each formed, in their outer sections, with asingle slot114f,115f,and with twoprojections114g,115gon each side of respective slot also engageable with recesses in the bottom wall. In addition, the inner sections of the twosheets114,115 are also formed withend flaps114i,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 twofurther cardboard sheets116,117 illustrated inFIG. 3 are adhesively coated, as shown by the dotted lines, and are of a configuration to be adhesively joined to the inner surfaces of the inner sections ofsheets112,113 serving as thelongitudinal side walls102,103 ofarticle100.Sheets116,117 serve to reinforce these longitudinal side walls and therefore are preferably also are of corrugated cardboard, with the corrugations running perpendicularly to those insheets112,113.
Sheet118 illustrated inFIG. 3 is the upper sheet of thebottom wall105 in the three-dimensional article100 illustrated inFIG. 1. It is formed with acentral fold line118ato permit the sheet to be folded into two sections and secured tobottom wall sheet118 by an adhesive118b;sheet118 is formed withrecesses118con its outer edges for receivingprojections112g-115gof the side wall sheets112-115.Sheet118 is further formed withbendable flaps118dat its opposite ends, to be received between the two sections of each of the transverse end walls ofsheets114,115.
It will be seen that whensheet118 is folded along its fold lines and adhesively joined at itsouter sections118btosheet111, themiddle sections118eare forced to an erect position in folded relation to each other to constitute thelongitudinal partition108, with the folded edge alongfold lines118aexposed for view (rather than a cut edge), and with the slots108ffor receiving thetransverse partitions106.
FIG. 4 illustrates the folded and adhesively-joined condition of the partitions106-108.FIG. 5 is a top view of thebase sheet110 in its flat condition when constructed as described above, andFIG. 6 is a bottom view ofbase sheet110.FIG. 7 illustrates thebase sheet110 in its substantially flat condition except thatsheet118 is in its folded condition aboutfold lines118ato define thelongitudinal partition108, and with theother partitions106 and107 in proper position to show how these partitions cooperate with each other and the various elements of the base sheet.
FIGS. 8a-8iillustrate the sequence of operations involved in assembling the three-dimensional article100 illustrated inFIG. 1 from thebase sheet110 and thepartitions106 and107. As described above, the article, when so assembled, has a high degree of dimensional rigidity and structural stability, and also presents a pleasing appearance, particularly since all edges of the article are defined by fold lines, and not by cut edges. The surfaces of the various sheets involved to appear as outer surfaces in the three-dimensional article100 may be colored or otherwise ornamented to enhance the aesthetic appeal of the assembled article.
The Embodiment of FIGS.9-21FIGS. 9-21 illustrate the invention embodied in a construction for producing a square-shaped three-dimensional article, generally designated200 inFIG. 9. Such an article may be used as a simple container or storage device, or as a modular unit for assembly, with other like modular units, into wall-mounted or floor-mounted shelving, bookcase, cabinet, and the like.
The three-dimensional article200 illustrated inFIG. 9 includes a squarebottom wall201, and four side walls202-205 to be folded into an erect position around thebottom wall201.Article200 is made of corrugated cardboard, and is constituted of asingle base sheet210 illustrated inFIG. 10. As described below,base sheet110 is constructed of a plurality of cardboard sheets each cut according to a predetermined configuration, and joined together at selected surfaces.Base sheet110 includes a predetermined arrangement of fold lines, to enable the sheet also to be supplied in flat form and to be formed into a three-dimensional article, e.g.,article200 illustrated inFIG. 9, having a high degree of dimensional stability and structural rigidity, as well as exposing only fold lines, rather than cut edges, to present a pleasing appearance.
As shown inFIG. 10,base sheet210 includes acentral section211 serving as thebottom wall201 ofarticle200, and four sections212-215 serving as the side walls202-205 of the article.Base sheet210 is constructed of several cardboard sheets, as more particularly illustrated inFIGS. 11-13, joined together at selective adhesively-coated surfaces to enable the base sheet, by simple folding operations, to be formed into the three-dimensional article200 illustrated inFIG. 9.
Thus, as shown inFIG. 11,base sheet210 is constituted of acentral sheet221 defining the bottom201 ofarticle200, and four additional sheets222-225, defining the four side walls202-205 ofarticle200. In this case, the three-dimensional article200 so produced is of a modular construction, as illustrated inFIGS. 15aand15b,permitting a plurality of similar units to be assembled in a modular manner, as illustrated inFIG. 15cand also inFIGS. 20 and 21. For this reason, thecentral sheet221 is of square configuration but includes a cut-out221aat one corner to provide the modular feature, as will be described below.
Base sheet210 includes a furthertop sheet226 which is adhesively joined over the upper surface of thecentral sheet221.Top sheet226 is similarly formed with a cut-out226ain one corner to be in alignment with cut-out221aof thecentral sheet221 whensheet226 is adhesively joined tosheet221. The corrugations insheet226 are perpendicular to those insheet221 for strengthening purposes. In addition, the outer edges of thetop sheet226 are formed withrecesses226b,to serve as recesses in the outer edges of thecentral sheet221 when joined thereto. These recesses are cooperable with projections in sheets222-225 when the latter sheets are folded to an erect position to define the side walls202-205 ofarticle200, as will be described more particularly below.
Base sheet210 includes twofurther cardboard sheets227,228, adhesively joined to the inner surfaces of the outer sections ofopposed sheets224,225 for strengthening purposes.Sheets227,228 may therefore also be of corrugated cardboard, but with the corrugations running perpendicularly to the corrugations in the outer sections ofsheets224,225.
Base sheet210 includes further strengtheningstrips229 applied to the inner surfaces of the outer edges of the outer twoopposed sheets222,223, for strengthening those edges. Strengtheningstrips229 may therefore also be of corrugated cardboard, with the corrugations running perpendicularly to those in theirrespective sheets222,223.
The twosheets222,223, defining the twoopposed side walls202,203 of the three-dimensional article200, are of the same construction except for a slight modification insheet223 to provide the modular feature. Similarly, the twosheets224,225, defining the other opposed side walls of the three-dimensional article200, are also of basically the same construction, except for a slight modification insheet224 to provide the modular feature.
As seen inFIG. 11, the four sheets222-225 include adhesively-coatedportions222a-225a,along their inner edges for adhesively joining to the outer edges of thecentral sheet221. In addition, the four sheets222-225 include mid-fold lines222b-225bdividing the respective side wall into aninner section222c-225cand anouter section222d-225d,foldable over the inner section. The edge of eachouter section222dand223dis further formed with projections222eand223e,whereas the outer edges ofsheets227 joined to theouter sections224dand225dofsheets224 and225, are also formed withprojections224dand225d.These projections are engageable with therecesses226bdefined by theupper sheet226 when bonded to thelower bottom sheet221 to firmly support the side walls in an erect position.
Sheet222 definingside wall202 is further formed with ahook formation222fat each of the opposite ends of itsouter section222d.Sheet222 is further formed with aflap222gat each of the opposite ends of itsinner section222c.Flaps222gare to be folded over the inner face of theinner section222cof the respective sheet and adhesively joined thereto for strengthening purposes.
Theopposed sheets223 defining theopposite side wall203 ofarticle200 is similarly constructed as described above with respect tosheet222, except that it is formed with slots223h-223jto provide the modular feature inarticle200.
The twosheets224,225, defining the other pair ofopposed side walls204,205 ofarticle200, 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 withrecesses226bin the bottom wall whensheets224 and225 are folded over to define theside wall204 and205 of the article.
The inner sections of the twosheets224 and225 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 inFIG. 11,sheet225 at the opposite side ofarticle200 is constructed in the same manner assheet224, except thatsheet224 is provided withvarious slots224i,224j,224k,to accommodate the modular feature.
FIG. 12 illustrates the inner face of thebase sheet210 when constructed as described above, andFIG. 13 illustrates the outer surface of the base sheet.
FIGS. 14a-14dillustrate the sequence of folding operations for folding the base sheet into the three-dimensional article200 illustrated inFIGS. 15aand15d.
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 ofprojections222e-225einto therecesses226bin the bottom wall of the article, by the engagement of the hook projections corresponding to222finto the recesses corresponding to224g,and by the engagement of projections corresponding to224hin therecesses224f.It will also be seen that the all the interengaging projections are concealed by the folded over outer sections of each of the sheets222-225; 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-out221ain thebottom wall221, 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.FIGS. 15a-19 illustrate various constructions, designated200a-200d,respectively, that can be provided for the modular construction; andFIGS. 20 and 21 illustrate various modular configurations that can be assembled using a plurality ofunits200.
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.