Abstract:
An apparel folding device suitable for folding apparel in a quick and consistent manner is disclosed. The device comprises a first panel hingedly connected to two side panels located on opposing sides. A bottom panel hingedly connected to the first panel may also be provided between the two side panels. The bottom panel and two side panels may each include a lipped handle. In addition, each of the two side panels may be constructed from two sub-panels. This permits the device to be shipped in a more compact and smaller package. The entire apparatus lays flat against a work surface when in its unfolded condition. The bottom panel and two side panels may include a raised member to facilitate grasping of the panel. By manipulating the panels in a predetermined order, apparel may be folded.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-In-Part of and claims the benefit of application Ser. No. 29/162,790 filed on Jun. 20, 2002, now U.S. Pat. No. D. 475,193 and incorporates the disclosure of same by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to apparel folding devices. More particularly, the present invention relates to a manually operated device for folding shirts and other articles of apparel in a quick and consistent manner. The device consists of a plurality of panels upon which an unfolded garment may be placed. By successively folding and unfolding the panels in a predetermined pattern, a user may fold the article. 
     In both a commercial and personal setting, it is often desirable to quickly and efficiently fold shirts, for example, in a compact and uniform matter. In the commercial setting, such folding enables employees to quickly set up aesthetically pleasing garment displays. Also, it is well known that shoppers routinely disrupt the uniform appearance of folded garments on display while browsing through stores. It is thus very important for an employee to be able to recompile clothing displays quickly and efficiently, throughout the shopping day. 
     Other commercial settings also call for the quick and efficient folding of shirts. For example, a commercial silk screener may have an order for a number of shirts in which a particular design may be placed. Prior to packaging and delivering the shirts, it is often desirable to fold the shirts in a uniform manner, perhaps even with the silk screened image exposed. Thus, when received by the final customer, a neat and orderly appearance is maintained. 
     In the personal setting, many homemakers are also desirous of folding shirts quickly, efficiently and in a uniform manner. This is especially true where shirts may be placed on shelves, which are visible to the home&#39;s occupants and guests, but may also be the case where such shirts are to be placed in a drawer. For large families, the need for efficiency is increased. 
     Various devices have been created to assist with the folding of garments in a quick, efficient and uniform manner. Despite these devices, there remains a need for a simple, inexpensive and efficient apparel folding device. There also remains a need for an apparel folding device that may be shipped in a compact manner. 
     SUMMARY OF THE INVENTION 
     The present invention addresses these needs. One embodiment of the apparel folding device of the present invention comprises a panel having first and second side edges, a first side panel hingedly engaged with the panel along its first side edge, and a second side panel hingedly engaged with the panel along its second side edge. At least one of the first side panel and the second side panel includes a handle member, such as a lipped handle, that extends above the surface of the respective side panels. An article of apparel may be folded using the apparel folding device by placing the article of apparel on the device and successively flipping and unflipping the first side panel and second side panel. 
     The apparel folding device may also comprise first and second end edges with a bottom panel hingedly engaged to the panel along its second end edge. If so provided, at least one of the bottom panel, the first side panel, and the second side panel may include a handle member that extends above the surface of the respective panel. An article of apparel may be folded using the apparel folding device by placing the article on the device and successively flipping and unflipping the first side panel, said second side panel and bottom panel. 
     The bottom panel may include a handle member that extends above the surface of the bottom panel. If so provided, at least one of the first side panel and the second side panel may include a cut out adapted to permit the handle member of the bottom panel to protrude therefrom when the respective side panel is folded. 
     The first side panel may comprise a first upper side panel and a first lower side panel and a second side panel may comprise a second upper side panel and a second lower side panel. The first upper side panel may be capable of being connected to the first lower side panel and the second upper side panel may be capable of being connected to the second lower side panel. The first upper side panel may also be detached from the first lower side panel and the second upper side panel may also be detached from the second lower side panel. 
     The first side panel may also comprise a first upper side panel and a first lower side panel and the second side panel may comprise a second upper side panel and a second lower side panel where the first upper side panel is hingedly engaged with the first lower side panel and the second upper side panel is hingedly engaged with the second lower side panel. 
     The first upper side panel may include a raised plateau forming a plurality of voids and the first lower side panel may include a plurality of self-locking protrusions extending therefrom. The self-locking protrusions may engage the voids to firmly attach the first upper side panel to the first lower side panel. The self-locking protrusions may include a first extension and a second extension. The first extension may comprise an elongated first extension first section adjacent to the first lower side panel at its proximal end and a first under cut at its distal end. The first extension and second extension may be separated by a gap. The raised plateau may be placed above the first lower side panel in engagement with the self-locking protrusions such that the voids are located completely below the under cuts. 
     As previously stated, the first side panel may comprise a first upper side panel and a first lower side panel and the second side panel may comprise a second upper side panel and second lower side panel. The first upper side panel may be hingedly engaged with the first lower side panel and the second upper side panel may be hingedly engaged with the second lower side panel. 
     At least one of the panel, first side panel or second side panel of the apparel folding device may include a display surface. If so provided, the bottom panel may also include a display surface. 
     The first side panel and the second side panel may form apertures therein. If so provided, the bottom panel may also form apertures therein. 
     In another embodiment, an apparel folding device comprises a panel having first and second side edges, a first side panel hingedly engaged with the panel along the first side edge, and a second side panel hingedly engaged with the panel along the second side edge. The first side panel may comprise a first upper side panel and a first lower side panel and the second side panel may comprise a second upper side panel and a second lower side panel. The first upper side panel and the first lower side panel may be capable of being stacked on one another to form a first stack and the second upper side panel and second lower side panel may be capable of being stacked on one another to form a second stack. The first stack and second stack may be capable of being placed on the panel to facilitate shipping and storage of the apparel folding device. The first upper side panel and first lower side panel may be hingedly engaged to each other at all times. Similarly, the second upper side panel and second lower side panel may be hingedly engaged to each other at all times. In other embodiments, the first upper side panel may be separated from the first lower side panel and the second upper side panel may be separated from the second lower side panel. 
     The panel of the apparel folding device of this embodiment may also comprise first and second end edges. There may also be provided a bottom panel hingedly engaged with the panel along the second side edge. If so provided, the bottom panel may be capable of being placed upon the panel to facilitate shipping and storage of the apparel folding device. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded perspective view of an apparel folding device in accordance with the first embodiment of the present invention. 
     FIG. 2 is an enlarged side elevational view of a self locking protrusion of the present invention; 
     FIG. 3 is a top perspective view of an apparel folding device in accordance with the second embodiment of the present invention; 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following is described the embodiments of the apparel folding device of the present invention. In describing the embodiments illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. 
     In this context, the apparel folding device may be constructed of any relatively rigid material such as various plastics, metals, woods, or the like. For purposes of this application, however, the apparel folding device will be referred to as if constructed of plastic. 
     Similarly, many types of garments may be folded using this device. However, this application will generally refer to shirts. Yet, it is to be understood that this device may be used to fold sweaters, pants, shorts and scarves, among other garments. 
     Finally, it is to be understood that although the invention is hereinafter described with two-part hinges, many hinges may be utilized. For example, depending on the panel material, living hinges may be utilized. Such hinges are commonly known in the industry. They are generally created by the placement of a thin portion of material bridging two heavier portions of the same material. They provide the ability to flex repeatedly without the use of a mechanical hinge. Other hinges contemplated include butt hinges, slip hinges, continuous hinges, flag hinges, liftoff hinges, and many other hinges generally known in the industry. Preferably, the hinges are detachable to facilitate shipping of the apparel folding device. 
     Referring to the figures, FIG. 1 depicts an exploded perspective view of an apparel folding device in accordance with the first embodiment of the present invention. The apparel folding device  2  preferably comprises a first panel  4 , bottom panel  6 , and first  8  and second  10  opposing side panels. 
     The first panel  4  comprises a continuous edge  12 . The continuous edge  12  comprises a first edge  14  and an opposing second edge  16 . A third edge  18  and opposing fourth edge  20  are oriented transverse to the first and second edges  14 ,  16  of the first panel  4 . 
     The first edge  14  is adjacent to the first side panel  8 , the fourth edge  20  is adjacent to the bottom panel  6 , and the second edge  16  is adjacent to the second side panel  10 . On each of the first edge  14 , fourth edge  20 , and second edge  16 , there is preferably located a pair of receiving hinges  21 A through  21 F. More particularly, receiving hinges  21 A and  21 B are located on first edge  14 , receiving hinges  21 C and  21 D are located on fourth edge  20 , and receiving hinges  21 E and  21 F are located on second edge  16 . As will be described hereinafter, the receiving hinges mate with hinged members of the other panels to permit rotation of these other panels relative to the respective edges of the first panel  4 . It will also be appreciated that a single hinge of the types previously discussed, particularly living hinges, may be used. 
     First panel  4  may also preferably contain a series of apertures  22  extending therethrough. The apertures  22  provide weight and material savings while still permitting the panel to have sufficient rigidity for its intended purpose. In addition, the apertures  22  facilitate the folding of apparel when the apparel folding device is in use by permitting air to flow therethrough. This air penetration prevents garments (not shown) from adhering to the panel  4  as it is unfolded. Although shown as slots, the apertures  22  may be in the form of virtually any shape including circles, squares, stars, and the like. The apertures may be dispersed in a uniform pattern, as shown in the figures, or may be randomly dispersed. 
     First panel  4  also may preferably comprise a display surface  24 . The display surface may be utilized to display any number of graphical images, but is typically utilized to display the name of the apparel folding device product  2  and information regarding the manufacturer. 
     Rotatably engaged along the fourth edge  20  of first panel  4  is bottom panel  6 . Bottom panel  6  comprises a first edge  26  and an opposed second edge  28 . Third edge  30  and opposed fourth edge  32  are oriented transverse to the first  26  and second  38  edges. The third edge  30 , located adjacent to the fourth edge  20  of first panel  4 , contains a pair of hinged members  34 A and  34 B which rotatably engage receiving hinges  21 C and  21 D of first panel  4 . This rotatable engagement permits bottom panel  6  to rotate relative to fourth edge  20  of first panel  4 , when so desired. 
     Along the fourth edge  32  of bottom panel  6  is preferably located lipped handle  36 . The lipped handle  36  is a crescent shaped member, which rises from the surface of bottom panel  6 . The lipped handle  36  is designed to enable a user to easily grasp bottom panel  6  to facilitate rotation of same. By providing such a raised handle  36 , bottom panel  6  may lie completely flat against a work surface (not shown), yet still permit a user to easily grasp it of course, feet capable of lifting the panel  6  may also be provided. 
     As with first panel  4 , bottom panel  6  also comprises a series of apertures  38  and a display surface  39 . The apertures  38  are typically identical to the apertures  22  of first panel  4 , although they need not be. Further, the display surface  39  of bottom panel  6  is typically similar to the display surface  24  of first panel  4 . However, this display surface  39  generally includes graphically illustrated instructions designed to teach a user how to use the apparel folding device  2 . 
     As shown in FIG. 1, adjacent to the first edge  14  of first panel  4  is located first &#39;side panel  8 . In the first, and preferred embodiment of the present invention, side panel  8  is comprised of a first upper side panel  40  and a first lower side panel  42 . This permits the panel to be shipped as two separate pieces, thus reducing the length of the package required to ship the device. The first upper side panel  40  comprises a first edge  44  located parallel and adjacent to the first edge  14  of first panel  4 . The first upper side panel  40  also comprises a second edge  46  extending perpendicular to the first edge  44 . A third edge  48  extends from the end of the second edge  46  opposite to the first edge  44  along an arcuate path and ends at the opposite end of first edge  44 . Each of the three edges  44 ,  46 ,  48  combine to form an essentially square first upper side panel  40 . 
     The first lower side panel  42  comprises a first edge  50  located parallel and adjacent to the first edge  26  of bottom panel  6 . The first lower side panel  42  also comprises a second edge  52  extending perpendicular to the first edge  50 , and adjacent to second edge  46  of first upper side panel  40 . A third edge  54  extends from the end of the second edge  52  opposite to the first edge  50  along an arcuate path and ends at the opposite end of first edge  50 . As shown in FIG. 1A, each of the edges  50 ,  52 ,  54 , combine to form an essentially square first lower side panel  42 . 
     As with the previous panels, first upper side panel  40  and first lower side panel  42  also preferably contain a series of apertures  56 . The apertures  56  are typically identical to the apertures  22  of first panel  4  and  38  of bottom panel  6 , although they need not be. 
     First lower side panel  42  is provided with a lipped handle  58  and an arcuate cutout  60  along its third edge  54 . The lipped handle  58  is typically crescent shaped, similar to lipped handle  36  of bottom panel  6 . In this regard, the lipped handle  36  is designed to enable a user to easily grasp first lower side panel  42  to facilitate rotation of same. By providing such a raised handle  58 , first lower side panel  42  may lie completely flat against a work surface (not shown) of course, feet may also be provided. The arcuate cutout  60  is preferably provided in first lower side panel  42  so that when the panel  42  is rotated towards first panel  4  and bottom panel  6 , lipped handle  36  of bottom panel  6  may protrude therethrough. This enables first side panel  8  to lie completely flat against first panel  4  and bottom panel  6 , when in a folded condition. 
     As is show in FIG. 1, the second edge  46  of first upper side panel  40  is raised from the third edge  48  and the first edge  44 . The second edge  46  is raised a distance equal to the thickness of first lower side panel  42 , and results in the formation of a raised plateau  61  extending from second edge  46 . Plateau  61  contains a plurality of circular apertures  62 . 
     Along second edge  52  of first lower side panel  42  are disposed a plurality of self locking protrusions  64 . Each self locking protrusion  64  is aligned with an aperture  62  on plateau  61 . First upper side panel  40  may be connected to first lower side panel  42  by placing the protrusions  64  of the first lower side panel through the circular apertures  62  of the first upper side panel  40 . Such placement will lock the two panels  40 ,  42  together. It will be appreciated that when the panels  42 ,  44  are connected, the apparel folding device  2  lays completely flat against a work surface (not shown), when in its open condition, unless feet are provided. 
     FIG. 2 depicts a detailed illustration of a self locking protrusion  64 . Each self locking protrusions  64  preferably consists of two extensions  66  extending normal to the upper surface of first lower side panel  42 . Each extension preferably begins with a first section  68  extending from the first lower side panel  42  and ends with a second section  70 . The second section  70  contains an undercut  72 . Between each extension  66  lies a gap  74 . 
     In order to connect first upper panel  40  to first lower side panel  42 , the circular apertures  62  are placed above the self locking protrusions  64 . Upon the application of pressure along the plateau  61  of first upper panel  40 , each extension  66  will flex inwards to close gap  74  and the circular apertures will pass over the undercuts  72  to a point adjacent to first section  68 . Once the undercuts  72  are cleared, the extensions  66  will spring back to their natural state and the undercuts  72  will prevent first upper side panel  40  from becoming separated from first lower side panel  42  as the undercuts are of a greater diameter than the apertures  62  when in their natural, unflexed condition. It will be appreciated that to achieve the tightest fit possible, the first section  68  of each self locking protrusion  64  is of a length only slightly greater than the thickness of plateau  61 . 
     Referring back to FIG. 1, the first edge  44  of first upper side panel  40  contains a pair of hinged members  76 A,  76 B. The hinged members  76 A,  76 B of first upper side panel  40  rotatively engage receiving hinges  21 A and  21 B of first panel  4 . This engagement allows first side panel  8  to freely rotate relative the first edge  14  of first panel  4 . 
     Second side panel  10  is constructed in much the same manner as first side panel  8 . However, it will be appreciated that second side panel  10  is located adjacent to second edge  16  of first panel  4 . 
     In the first, and preferred embodiment of the present invention, side panel  10  is comprised of a second upper side panel  80  and second lower side panel  82 . The second upper side panel  80  comprises a first edge  84  located parallel and adjacent to the second edge  16  of first panel  4 . The second upper side panel  80  also comprises a second edge  86  extending perpendicular to the first edge  84 . A third edge  88  extends from the end of the second edge  86  opposite to the first edge  84  along an arcuate path and ends at the opposite of first edge  84 . As shown in FIG. 1, each of the three edges  84 ,  86 ,  88  combined to form an essentially square second upper side panel  80 . 
     The second lower side panel  82  comprises a first edge  90  located parallel and adjacent to the second edge  28  of bottom panel  6 . The second lower side panel  82  also comprises a second edge  92  extending perpendicular to the first edge  90 , and adjacent to the second edge  86  of second upper side panel  80 . A third edge  94  extends from the end of the second edge  92  opposite to the first edge  90  along an arcuate path and ends at the opposite end of first edge  90 . As shown in FIG. 1, each of the edges  90 ,  92 ,  94  combine to form an essentially square second lower side panel  82 . As with the previous panels, second upper side panel  80  and second lower side panel  82  also contain a series of apertures  96 . The apertures  96  are typically identical to the apertures  22  of first panel  4 , the apertures  38  of bottom panel  6 , and the apertures  56  of first upper side panel  40  and first lower side panel  42 , although they need not be. 
     Second lower side panel  82  is also preferably provided with a lipped handle  98  and an arcuate cutout  100  along its third edge  94 . The lipped handle  98  is typically crescent-shaped, similar to the lipped handle  36  of bottom panel  6 , and the lipped handle  58  of first lower side panel  42 . In this regard, the lipped handle  98  is designed to enable a user to easily grasp second lower side panel  82  to facilitate rotation of same. By providing such a raised handle  98 , second lower side panel  82  may lie completely flat against a work surface (not shown), if feet are not provided. The arcuate cutout  100  is preferably provided in second lower side panel  82  so that when the panel  82  is rotated towards first panel  4  and bottom panel  6 , lipped handle  36  of bottom panel  6  may protrude therethrough. This enables second side panel  10  to lie completely flat against first panel  4  and bottom panel  6 , when in its folded condition. 
     Although the invention has been described as preferably including crescent-shaped lipped handles  36 ,  58 ,  98 , it will be appreciated that any member which extends beyond the upper surface of the respective panel will suffice. Crescent-shaped lipped handles are merely preferable. 
     As with first upper side panel  40 , in the preferred embodiment, the second edge  86  of second upper side panel  80  is raised from the third edge  88  and the first edge  84 . The second edge  86  is raised a distance equal to the thickness of the lower side panel  82 , and results in the formation of a raised plateau  101  extending from second edge  86 . Plateau  101  contains a plurality of circular apertures  102 . 
     Along second edge  92  of second lower side panel  82  are disposed a plurality of self locking protrusions  104 . Each self locking protrusion is aligned with an aperture  102  on plateau  101 . Second upper side panel  80  may be connected to second lower side panel  82  by placing the protrusions  104  of the second lower side panel through the circular apertures  102  of the second upper side panel  80 , thus locking the two panels  80 ,  82  together. It will be appreciated that in the preferred embodiments, when the panels  80 ,  82  are connected, the apparel folding device  2  lays completely flat against a work surface (not shown), when in its open condition. Of course, feet may be provided on the bottom of the panels, if so desired. 
     The self locking protrusion  84  of second lower side panel  82  are identical to the self locking protrusions  64  of first lower side panel  42 , as shown in FIG.  2 . 
     The first edge  84  of second upper side panel  80  contains a pair of hinged members  106 A and  106 B. The hinged members  106 A and  106 B of second upper side panel  80  rotatingly engage receiving hinges  21 E and  21 F of first panel  4 . This engagement allows second side panel  10  to freely rotate relative the second edge  16  of first panel  4 . 
     While FIG. 1 depicts a top prospective view of an apparel folding device in accordance with the first embodiment of the present invention, FIG. 3 depicts a prospective view of a folding device in accordance with the second embodiment of the present invention. In this embodiment, first side panel  8  and second side panel  10  are each formed from a single sheet of material. Typically, this is a result of a single monolithic pour of material. As with the previous embodiment, the apparel folding device of the second embodiment lays completely flat when in its opened condition, unless feet are provided. 
     The preferred embodiment has the advantage of being shipped in a more compact manner than the second embodiment. For example, in the preferred embodiment, the apparel folding device  2  may be shipped in a box (not shown) which is substantially the same size as first panel  4 . In this regard, first upper side panel  40  and first lower side panel  42  will either not be connected to each other, or will be folded along second edge  46  of first upper side panel  40  and second edge  52  of first lower side panel  42 . Likewise, second upper side panel  80  and second lower side panel  82  will either be shipped apart from each other, or will be folded together along second edge  86  of second upper side panel  80  and second edge  92  of second lower side panel  82 . The four side panels  40 ,  42 ,  80 ,  82  may then be placed upon first panel  4  in a stacked configuration. Finally, bottom panel  6  may be similarly placed on the stack. It will be appreciated that this stack may then be placed in a box (not shown) which is not substantially larger than first panel  4 . 
     In the second embodiment, the apparel folding device  2  must be shipped in a larger box. This box will be approximately the same size as first side panel  8  and first side panel  10 , as these side panels are not separable. 
     In a third embodiment, the apparel folding device  2  may only comprise three panels, namely, first panel  4 , first side panel  8  and second side panel  10 . It will be appreciated that the remaining aspects of each of these panels may coincide with those found in the first and second embodiments. In this regard, first side panel  8  may comprise first upper side panel  40  and first lower side panel  42 , as in the first embodiment, or may be a single panel as in the second embodiment. Similarly, second side panel  10  may comprise second upper side panel  80  and second lower side panel  82 , as in the first embodiment, or may be a single panel as in the second embodiment. 
     To use the apparel folding device  2 , a user should place the garment, for example a shirt (not shown), on the unfolded device. After centering the garment (not shown), the user may successively fold and unfold each side panel  8 ,  10 , and then the bottom panel  6  (if provided). This will result in the garment (not shown) being folded. It will be appreciated that to facilitate a user grasping the panels  6  (if provided),  8 ,  10 , each is provided with a lipped handle  36 ,  58 ,  98 . Apertures  38 ,  56 ,  96  may also be provided to permit air to flow through the panels  6  (if provided),  8 ,  10 . This prevents the garment from adhering to the panels  6  (if provided),  8 ,  10  as they are being unfolded. 
     Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.