Abstract:
A generally planar ornamental structure is formed by dividing a large common panel into subpanels at fold lines, and cutting individual lines through each of the subpanels. The subpanels are then folded on each other in an accordion-like structure to form overlapping subpanels, providing a desired design configuration. This can be used to form, for example, an ornamental box lid, a greeting card or a portion of a book, such as a child&#39;s book.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Very unique, artistic designs can be formed by layering generally planar panels, such as paper stock, on top of each other. A unique design can be formed by cutting out portions of each panel and then stacking one on top of the other, so that the cutout portions combine to form a multilayered cutout structure with an aesthetically appealing design. 
         [0002]    These multilayered designs can be employed in a variety of different articles, such as children&#39;s books, greeting cards, merchandising items such as displays, boxes and the like. Unfortunately, these types of designs tend to be relatively expensive to produce, particularly in limited quantities. Separate individual panels must be cut out and then subsequently aligned and combined together to provide the desired end product. The time required to do this increases the cost significantly. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention is based on the discovery that a multilayer planar cutout structure can be formed by first cutting out two or more separate designs on a single common panel and forming one or more fold lines between the different designs to form smaller subpanels. The multilayer cutout structure is then formed by simply folding the subpanels onto each other at the fold lines. The cutout portions can be formed with a laser cutter or water jet cutter, or can be die cut. The fold lines can be established either before or after cutting. 
         [0004]    The fold lines are formed at precise locations to properly align the different cut outs as the subpanels are folded onto each other. Although not required, fold lines may define equally-sized, overlapping panels. 
         [0005]    Further, three or more panels can be formed from a single common panel with two or more fold lines and two or more different cutout patterns. The multiple cutout patterns can then be aligned together by folding the different subpanels in an accordion-type manner. This method allows for three or more overlapping designs. 
         [0006]    The method of the present invention ensures that the different cutout designs are very precisely aligned, improving product quality and reducing costs. 
         [0007]    Further, the top surface and the bottom surface of the common panel can be different colors to provide different effects, when the subpanels are folded on each other. The common panel may be printed with different designs, for example, with different colors, so that the first subpanel will be a first color, the second subpanel a second color and the third subpanel a third color. 
         [0008]    The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings, in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of the present invention; 
           [0010]      FIG. 2  is an overhead plan view of the flat common panel; 
           [0011]      FIG. 3  is an overhead plan view of the present invention; 
           [0012]      FIG. 4  is an exploded view of the embodiment shown in  FIG. 1 ; 
           [0013]      FIG. 5  is a cross-sectional view taken at lines  4 - 4  of  FIG. 1 ; 
           [0014]      FIG. 6  is a plan view of an alternate design of the present invention; 
           [0015]      FIG. 7  is a plan view of a second alternate design of the present invention; 
           [0016]      FIG. 8  is a plan view of a third alternate embodiment of the present invention; and 
           [0017]      FIG. 9  is an isometric view of a fourth alternate embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]      FIGS. 1-5  show a box having a lid incorporating the present invention. However, the present invention can be further utilized in a wide variety of different applications and certainly is not limited to formation of a box lid. This is merely an exemplary embodiment and the present invention can be further utilized in greeting cards, books and, in fact, any visual display. 
         [0019]    As shown in  FIG. 1 , a box  12  includes a lid or cover  14  and a base  16 . Box lid  14  includes an outer member  18 , an inner member or slip  20  and a generally planar insert  22 . The outer member  18  of lid  14  includes top panel  19  and four side walls  21   a,    21   b,    21   c,    21   d.  Likewise, the inner member  20  of lid  14  includes a top panel  23  and four side walls  24   a - d . As shown, the top panel  19  of the outer member  18  of lid  14  includes a plurality of cutout areas  25 , leaving a two-dimensional design, in this case, showing a plurality of hexagons  27 . 
         [0020]    The generally planar insert  22  is formed from a single common panel  28 , which has a first subpanel  30 , a second subpanel  32  and a third subpanel  34 , separated from each other by a first fold line  36  and a second fold line  38 . In this embodiment, the insert has three separate subpanels, however, common panel  28  could have only two subpanels separated by one fold line, or could have, for example, four subpanels separated by three fold lines, or even more. Further, the common panel and the subpanels are shown as rectangular. But they can be different shapes, such as circular or hexagonal, depending on the desired product. The fold lines are generally lines of weakness which facilitate folding. Usually they are simply pressed into the common panel. 
         [0021]    First panel  30  includes first cutout areas  40 , leaving a three-dimensional design  41  which, in this case, again is a series of hexagons. Likewise, second panel  32  includes second panel cutout areas  42 , which leave a design  43 , again hexagonal shapes. And finally, third panel  34  includes third panel cutout  44 , leaving design  45 . The design  43  in second panel  32  is reverse cut relative to design  41  and  45  in the first and third panels because of the manner it is folded, as described below. 
         [0022]    The common panel  28  can be formed from a variety of different materials, which can be cut through to form an ornamental design. In one embodiment, this common panel  28  can be formed from paperboard stock. The thickness is a matter of design choice. It can be simply paper or thicker cardboard stock, depending upon the desired end use and required durability. Further, the product can be formed from plastic materials and the like, assuming they have sufficient rigidity, to provide the desired end product and can be formed with fold lines. Common panel  28  includes a first surface  46 , referred to as a “top surface”, and a second surface (not shown), referred to as a “bottom surface”. The top surface  46  and bottom surface may have different colors to provide different appearances after folding the insert together. Further, the individual subpanels can have different colors on either the top surface of the bottom surface, or they can be illustrated, depending, again, upon the desired look of the end product. 
         [0023]    To form the insert  22 , the designs  41 ,  43  and  45  of the subpanels  30 ,  32  and  34 , are cut out through the top surface  46 , for example, using a laser cutter. The fold lines  36  and  38  can be formed into the cardboard stock, either before or after forming the cutouts  40 ,  42 ,  44 . 
         [0024]    As shown in  FIG. 4 , to form the multilayer overlapped panel  22 , the subpanels  30 ,  32  and  34 , with cutouts  41 ,  43  and  45  are folded relative to each other at fold lines  36  and  38 . The bottom surface  50  of panel  30  is folded at fold line  36  onto the bottom surface  52  of panel  32 . The top surface  54  of panel  34  is folded at fold line  38  onto the top surface  56  of panel  32 . This aligns cutout designs  41 ,  43 , and  45  over each other. Once folded together, multilayer overlapped panel  22  is placed between the outer member  18  and inner member or slip  20  of the lid  14  on panel  23 . Panel  23  of inner member  20  is shown as a solid panel. However, it can also have a cutout or printed ornamental design which will show through any aligned cutout areas of panels  30 ,  32  and  34 . 
         [0025]    Outer member  18  is then placed over this assembly, with the panel  19  of the outer member  18  resting directly on the first panel  30  of overlapped panel  22 . 
         [0026]    Outer member  18  of lid  14  fits over inner member  20 , with the sidewalls  21   a - d  of the outer member  18  alongside the sidewalls  24   a - d  of the inner member  20 . The respective sidewalls  21   a - d  and  24   a - d  are adhered together, trapping the overlapped folded multilayered panel  22  on panel  23  of inner member  20 . 
         [0027]    The design of the end product is more particularly shown in  FIGS. 1 and 3 . As can be seen, the hexagonal design  27  in panel  19  of the outer member  18  of the lid aligns with a slight offset with the design portions  41 ,  43 ,  45  of the subpanels  30 ,  32  and  34  providing a slightly staggered three-dimensional effect. The panel  19  further includes a portion  57  that allows for indicia or other packaging. However, this is merely exemplary and any design can be incorporated into the respective surfaces. 
         [0028]      FIGS. 6 ,  7  and  8  show alternate embodiments of the overlapped multi panel of the present invention. As shown in  FIG. 5 , the lid  60  includes a top cutout design  62 . A ribbon  64  and tag  66  are attached to the lid at a display area  68 . Beneath design  62  cut through the top layer of lid  60  are design areas  68 ,  70 ,  72 , resting on surface  74 . 
         [0029]    As with the embodiment shown in  FIGS. 1-5 , the designs  70 ,  72  and  74  are cut through a common panel which is folded in the same manner shown in  FIG. 3 . In the embodiment shown in  FIG. 6 , the design is different. 
         [0030]    Likewise,  FIGS. 7 and 8  show the same structure depicted in  FIGS. 1-4  but with different designs. 
         [0031]    The multilayered panel  22  can be used as part of a greeting card  80 , as shown in  FIG. 9 , where panel  22  is held by a cutout panel  84  (similar to top panel  19  of lid  14 ) with a solid backing panel  86  on the cover  82  of the greeting card  80 . Regardless of the nature of the final product, the method of making overlapping panels  22  with cutouts that form intricate designs reduces costs and improves the end product by insuring that the subpanels are precisely aligned and can be assembled quickly. The end product can be utilized in a wide variety of different applications. 
         [0032]    This has been a description of the present invention. The invention itself should only be defined by the appended claims wherein we claim: