Abstract:
A baby play station has a planar mat portion having a plurality of side edges, and a plurality of walls, each wall having incorporated therewith a panel, and each wall having a lower side that is hingedly coupled to one of the plurality of side edges of the mat portion. Each panel includes a foldable frame member having a folded and an unfolded orientation, the frame member defining a periphery for the panel with an interior space inside of the peiphery, and a fabric material covering the interior space defined by the frame member to form the panel when the frame member is in the unfolded orientation.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to collapsible structures, and in particular, to a play station that can be used by babies, the play station capable of being folded and collapsed to a smaller size for storage. 
         [0003]    2. Description of the Prior Art 
         [0004]    There are presently many collapsible structures that are being provided for use by children and adults in a number of different applications. Examples of these collapsible structures are illustrated in the following patents: U.S. Pat. Nos. 5,816,954 (Zheng), 6,006,772 (Zheng), 5,778,915 (Zheng), 5,467,794 (Zheng), 5,975,101 (Zheng), 5,722,446 (Zheng), 4,858,634 (McLeese), 4,825,592 (Norman), 5,964,533 (Ziglar), 5,971,188 (Kellogg et al.), 6,485,344 (Arias), 6,343,391 (LeGette), U.S. Pub. No. 2004/0139997 (Zheng) and 5,038,812 (Norman), among others. These collapsible structures are supported by one or more frame members that can be twisted and folded to reduce the overall size of the structure. These collapsible structures can be used in a wide variety of applications, such as containers, tents, play structures, executive toys, shelters, sports structures, and others. As a result, collapsible structures have become very popular. 
         [0005]    Baby play stations have been provided where a baby can lie on a mat and play with toys suspended from bars that extend over the baby&#39;s body. These play stations cannot be folded or reduced in size, so they are often bulky and take up a lot of storage space when not in use. 
       SUMMARY OF THE DISCLOSURE 
       [0006]    It is an object of the present invention to provide a baby play station that can be folded and reduced in size for storage. 
         [0007]    In order to accomplish the objects of the present invention, the play station according to the present invention has a planar mat portion having a plurality of side edges, a plurality of walls, each wall having incorporated therewith a panel, and each wall having a lower side that is hingedly coupled to one of the plurality of side edges of the mat portion. Each panel includes a foldable frame member having a folded and an unfolded orientation, the frame member defining a periphery for the panel with an interior space inside of the peiphery, and a fabric material covering the interior space defined by the frame member to form the panel when the frame member is in the unfolded orientation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of a baby play station according to one embodiment of the present invention. 
           [0009]      FIG. 2  is an exploded perspective view of the play station of  FIG. 1 . 
           [0010]      FIG. 3  is a partial cut-away view of the section A from  FIG. 2  illustrating a frame member retained within a sleeve. 
           [0011]      FIGS. 4A through 4C  illustrate how a panel may be twisted and folded for compact storage. 
           [0012]      FIG. 5  is a partial cut-away view of the section B from of  FIG. 2  illustrating the support bar. 
           [0013]      FIG. 6  illustrates one embodiment of the support bar shown in  FIG. 2 . 
           [0014]      FIG. 7  illustrates a modification that can be made to the play station of  FIG. 1 . 
           [0015]      FIGS. 8A-8D  illustrate the steps for dis-assembling the play station of  FIG. 1 . 
           [0016]      FIG. 9  illustrates a stack of folded bar sections for the support bar. 
           [0017]      FIG. 10  illustrates additional modifications that can be made to the play station of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0018]    The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. 
         [0019]      FIG. 1  illustrates a baby play station  20  according to one embodiment of the present invention. The play station  20  has a mat portion  22  upon which a baby can lie, and four walls  24 ,  26 ,  28  and  30  that enclose the mat portion  22 . The mat portion  22  is made from a soft fabric material to provide comfort and safety to a baby who is lying on the mat portion  22 . As described in greater detail below, each wall  24 ,  26 ,  28 ,  30  is constructed of two layers of a soft fabric that defines a space inside therebetween, with a collapsible structure inserted inside the space between the two layers of fabric. The dimensions of the walls  24 ,  26 ,  28 ,  30  can be varied to create a rectangular or square play station  20 , depending on the configuration of the mat portion  22 . For example, as shown in  FIG. 1 , the two end walls  24  and  28  can be shorter in length than the two side walls  26  and  30  if the mat portion  22  is generally rectangular, and all four walls  24 ,  26 ,  28 ,  30  can be identical in size if the mat portion  22  is generally square. Each wall  24 ,  26 ,  28 ,  30  can have the same height, or their heights can be varied. 
         [0020]    The mat portion  22  has four side edges (e.g.,  32 ), and each of the four walls  24 ,  26 ,  28 ,  30  has a bottom side (e.g.,  34 ) that is stitched or otherwise hingedly connected to one of the four side edges of the mat portion  22 . For example, the end wall  24  can be folded up or down from the plane defined by the mat portion  22  at its hinged connection between its bottom side and the side edge  32  of the mat portion  22 . The other walls  26 ,  28  and  30  can all be hingedly connected to corresponding side edges of the mat portion  22  so that all four walls  24 ,  26 ,  28 ,  30  can be pivoted up or down about their hinged connections. 
         [0021]    Corner tuck pieces  40  are provided to connect the vertical sides of the walls  24 ,  26 ,  28 ,  30  to adjacent walls  24 ,  26 ,  28 ,  30 . These tuck pieces  40  are preferably made of the same material as the fabric for the walls  24 ,  26 ,  28 ,  30 . For example, the tuck piece  40  connects the vertical sides  42  and  44  of the adjacent walls  24  and  26 , respectively. Similarly, tuck piece  46  connects the vertical sides  48  and  50  of the adjacent walls  24  and  30 , respectively. Similar tuck pieces can be provided to connect the vertical sides of the end wall  28  to the other vertical sides of the side walls  26  and  30 . These tuck pieces  40  can be tucked in against the walls  24 ,  26 ,  28 , when the walls  24 ,  26 ,  28 ,  30  are folded against the mat portion  22  during storage. Removable connection mechanisms  35  (e.g., clips, hooks, VELCRO™ pads, and the like) are provided along the walls  24 ,  26 ,  28 ,  30  to secure the four walls  24 ,  26 ,  28 ,  30  in an upright orientation when the play station  20  is deployed in use. 
         [0022]    Each side wall  26 ,  30  is provided with one or more tubular pockets  52  for receiving the opposing ends of a generally inverted U-shaped support bar  54 . Each bar  54  is adapted to support (e.g., by suspending using conventional and known mechanisms) a plurality of baby toys  56 , such as rattles, mirrors, stuffed animals, etc. 
         [0023]      FIG. 2  illustrates the play station  20  shown with the collapsible structures removed from the space between the two layers of fabric in the walls  24 ,  26 ,  28 ,  30 . The collapsible structure can be embodied in the form of any of the panels  100 ,  102  or  104  shown in  FIG. 2 . Each wall  24 ,  26 ,  28 ,  30  is constructed of two layers  60 ,  62  of a soft fabric that defines a space inside therebetween, with a slit or opening  64  along one vertical side of the wall  24 ,  26 ,  28 ,  30 , so that the panel  100 ,  102 , or  104  can be inserted through the opening  64  to be positioned inside the space between the two layers  60 ,  62  of fabric, to removed from the space via the opening  64 . The panels  100 ,  102 ,  104  function to provide solidity to the walls  24 ,  26 ,  28 ,  30 . 
         [0024]    The panel  100  can have four sides, although the panel  100  can assume any configuration and have any number of sides (e.g., square, rectangular, oval). Referring to  FIGS. 2 and 3 , the panel  100  has a frame retaining sleeve  110  provided along and traversing the four edges of its four sides. A frame member  112  is retained or held within each respective frame retaining sleeve  110  to support the panel  100 . 
         [0025]    The frame member  112  may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The frame member  112  is preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame member  112  should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each frame member  112  is capable of assuming two positions or orientations, an open or expanded position such as shown in  FIG. 2 , or a folded position in which the frame member  112  is collapsed into a size which is much smaller than its open position (see  FIG. 4C ). The frame member  112  may be merely retained within the frame retaining sleeve  110  without being connected thereto. Alternatively, the frame retaining sleeve  110  may be mechanically fastened, stitched, fused, or glued to the frame member  112  to retain it in position. 
         [0026]    A fabric material  114  extends across the panel  100 , and is held taut by the frame member  112  when in its open position. The fabric material  114  is made from strong, lightweight materials and may include woven fabrics or nylons or a meshed material. The fabric material  114  should be water-resistant and durable to withstand the wear and tear associated with rough treatment. 
         [0027]      FIGS. 4A through 4C  describe the various steps for folding and collapsing the panel  100  for compact storage. The first step consists of twisting and folding to collapse the frame member  112  and panel  100  into a smaller shape. In particular, the opposite border of the panel  100  is folded in (see arrow  2  in  FIG. 4A ) upon the previous fold to further collapse the frame member  112  with the panel  100 . As shown in  FIG. 4B , the folding is continued so that the initial size of the panel  100  is reduced until the frame member  112  and panel  100  are collapsed on each other (see  FIG. 4C ) to provide for a small essentially compact configuration having a plurality of concentric frame members  112  and layers of the panel  100  so that the collapsed panel  100  has a size which is a fraction of the size of the initial structure. 
         [0028]    Referring back to  FIG. 2 , the panel  102  can be constructed with two panels  100  that are connected together by one or more fabric connectors  118 . The fabric connectors  118  can be made of the same material as the fabric material  114 . The panel  102  can be folded and collapsed by folding one panel  100  on top of the other panel  100 , with the fabric connector(s)  118  acting as a hinged connector, to create a stack of the two panels  100  that can be twisted and folded according to the steps shown in  FIGS. 4A-4C . 
         [0029]    The panel  104  can be constructed by one resilient frame member  120  that has been twisted into a Figure-8 configuration. Referring to  FIG. 2 , the frame member  120  comprises a closed resilient loop. To form the Figure-8 configuration, one end of the closed frame member  120  is grasped and twisted by 360 degrees with respect to the other end. The overlapping or cross-over portions of the frame member  120  may then be secured together at  122 , such as by riveting, stapling, sewing, or other conventional securing mechanisms, to hold the frame member  120  in the Figure-8 configuration. Alternatively, the overlapping portions of the frame member  120  may be left free and unsecured if the frame member  120  is retained in a frame retaining sleeve. When the frame member  120  is held in this configuration, two closed loops (see L 1  and L 2  in  FIG. 2 ) are defined, with the overlapping portion or point  122  acting as a hinge for the two closed loops. Each closed loop is substantially equal in size and symmetrically disposed. Depending on the size and shape of the frame member  120 , the closed loops may assume any variety of shapes, including circular or oval. Further, as shown in  FIG. 2 , when the frame member  120  is formed into this Figure-8 configuration, the two closed loops are biased to fold towards each other. A fabric material  128  extends across the plane of the panel  104  defined by the frame member  120 . 
         [0030]    The frame member  120  can be made from the same material as the frame member  112  described above, and can include flat spring steel stock, and in particular, stainless steel, although plastic may also be used. Referring to  FIG. 2 , the frame member  120  is retained in a frame retaining sleeve  126  that extends around and through panel  104  in a manner such that the frame member  120  is preferably held in tension. The frame retaining sleeve  126  may be formed by folding a peripheral edge of the fabric material  128  over the frame member  120  and then stitching, or by providing a separately-formed tubular sleeve that is stitched to the fabric material  128 . Alternatively, the frame member  120  may be mechanically fastened, glued or fused to the frame retaining sleeve  126 . 
         [0031]    The panel  104  can be folded and collapsed by folding one loop L 1  on top of the other loop L 2 , with the overlapping point  122  acting as a hinge, to create a stack of the two loops L 1 , L 2  that can be twisted and folded according to the steps shown in  FIGS. 4A-4C . 
         [0032]    The panels  102  and  104  can be used for longer walls, such as the side walls  26  and  30 , while the panel  100  can be used for any of the walls, but probably more suited for use with shorter walls, such as the end walls  24  and  28 . 
         [0033]    Referring to  FIG. 5 , the overall inverted U-shaped support bar  54  can be broken down into a plurality of bar sections  54   a ,  54   b , etc. Each alternating bar section (e.g.,  54   a ) has a tubular skeleton  130  and a cylindrical soft padding  132  wrapped around the skeleton  130 . The other alternating bar section (e.g.,  54   b ) has a bore  134  extending through its own skeleton  130  that is positioned inside its cylindrical soft padding  136 . The opposite ends  138 ,  140  of the skeleton  130  extend beyond the ends of the padding  132  so that each end  138 ,  140  can be inserted into an open end of a bore  134  of the adjacent bar section  54   b  to connect the bar sections  54   a ,  54   b  together. The ends  138 ,  140  have a smaller diameter than the diameter of the bores  134  to allow the ends  138 ,  140  to be inserted into the bores  134 . A tether  142  extends through the hollow bore of the skeletons  130  and the bores  134  of all the bar sections  54   a ,  54   b , etc. to couple or link all the bar sections  54   a ,  54   b , etc. together along a tether line. The tether  142  is preferably made from an elastic material to allow the tether  142  to be stretched and extended (e.g., as shown in  FIG. 9  below). 
         [0034]    As a result, the bar  54  can be deployed in two configurations, a first configuration where all the bar sections  54   a ,  54   b , etc. are joined together to form the unitary bar  54  as shown in  FIG. 2  for use in supporting play objects, and a second configuration where each bar section  54   a ,  54   b , etc. can be disengaged from each other. In this second configuration, the user can fold each bar section  54   a ,  54   b  one on top of the other so that the unitary bar  54  shown in  FIG. 2  is now collapsed into a short stack of bar sections  54   a ,  54   b , etc. that are compact enough for convenient storage, such as shown in  FIG. 9 . Removable connection mechanisms  145  (e.g., VELCRO™ straps, ties, straps, etc.) can be provided on each bar section  54   a ,  54   b , etc. to secure the bar sections  54   a ,  54   b , etc. together when deployed for use, such as shown in  FIGS. 1 and 2 . 
         [0035]      FIG. 6  shows one non-limiting embodiment of the bar  54 , with the bar  54  divided into three bar sections  54   a ,  54   b ,  54   c , with bar sections  54   a ,  54   c  being the same as bar section  54   a  shown in  FIG. 5 , and bar section  54   b  being the same as bar section  54   b  shown in  FIG. 5 . 
         [0036]      FIG. 7  illustrates a modification that can be made to the play station of  FIGS. 1 and 2 , where the two separate inverted U-shaped support bars  54  are replaced by a single set of crossing support bars  154 . The ends of the support bars  154  can still be inserted into the pockets  52  for support. 
         [0037]    Thus, the play station  20  according to the present invention provides significant benefit over the conventional play stations in that the play station  20  can be conveniently dis-assembled, packed up, and stored. In particular, from the normal use configuration shown in  FIG. 1 , the user can easily dis-assemble the play station  20  in the following manner: First, the various panels  100 ,  102  and/or  104  can be removed from the walls  24 ,  26 ,  28 ,  30 , and each of these panels  100 ,  102 ,  104  can be twisted and folded according to the steps in  FIGS. 4A-4C  to reduce their overall sizes. The support bars  54  or  154  can also be removed and detached into separate bar sections to form a stack of folded bar sections (see  FIG. 9 ). Next, as shown in  FIG. 8A , the longer side walls  26 ,  30  are folded inwardly onto the mat portion  22  (see  FIG. 8B ), and then the end walls  24 ,  28  are folded inwardly to be on top of the side walls  26 ,  30  and the mat portion  22  (see  FIG. 8C ). In the next step, the combined walls  24 ,  26 ,  28 ,  30  and mat portion  22  can be folded in half at about the center of the mat portion (see  FIG. 8D ). Finally, the separate components (folded walls  24 ,  26 ,  28 ,  30  and mat portion  22  from  FIG. 8D , the collapsed panels  100 ,  102 ,  104 , and the stack of folded bar sections from  FIG. 9 ) can be stored together in a bag or pouch (not shown) that is much smaller in size and shape than would otherwise be needed to stored the assembled play station  20 . 
         [0038]    As shown in  FIGS. 8C and 8D , handles  160  can be provided on the rear surfaces of the mat portion  22 . In such an embodiment, the collapsed panels  100 ,  102 ,  104 , and the stack of folded bar sections from  FIG. 9 , can be stored between the folded halves of the mat portion  22  so that the folded mat portion  22  can also act as a housing or carrying case for the play station  20 . 
         [0039]      FIG. 10  illustrates two optional features that can be provided for the play station  20  of  FIG. 1 . First, a meshed or other cover  144  can be draped over the top of the support bars  54  to shield the baby from flies and other insects. A panel  200 , which can be identical in construction to the panel  100 , can be stitched or otherwise secured to the cover  144 , and provided with attachment mechanisms  146  (e.g., hooks, VELCRO™ pads) that allow the panel  200  to be removably secured to the top of the support bars  54 . This allows the cover  144  to be secured to the support bars  54  in a manner which prevents the cover  144  from falling onto the baby. 
         [0040]    While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.