Collapsible panel assembly

An assembly includes a first panel and a second panel. Each panel has a foldable frame member having a folded and an unfolded orientation, with a fabric material covering selected portions of the respective frame member to form the respective panel when the respective frame member is in the unfolded orientation. A connection system is provided to removably connect the first and second panels.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to collapsible structures, and in particular, to a system for assembling or otherwise building objects from separate collapsible panels using connectors.

2. Description of the Prior Art

Collapsible structures have recently become popular with both adults and children alike. Examples of such structures are shown and described in U.S. Pat. Nos. 5,038,812 (Norman), 5,467,794 (Zheng) and 5,560,385 (Zheng). These structures have a plurality of panels that may be twisted and folded to reduce the overall size of the structures to facilitate convenient storage and use. As such, these structures are being enjoyed by many people in many different applications.

Most of these collapsible structures are pre-assembled with the panels connected to adjacent panels by stitching or other non-detachable connections. Therefore, it is not possible to change the configuration of the structure, so the variety of use and play for these structures can be limited.

Thus, there still remains a need for collapsible structures that provide increased variety of play, entertainment value, and utility.

SUMMARY OF THE DISCLOSURE

In order to accomplish the objects of the present invention, the present invention provides an assembly that includes a first panel and a second panel. Each panel has a foldable frame member having a folded and an unfolded orientation, with a fabric material covering selected portions of the respective frame member to form the respective panel when the respective frame member is in the unfolded orientation. A connection system is provided to removably connect the first and second panels.

In one embodiment, the connection system includes a flexible connector that is made of a different material than the frame members and the fabric material, with the flexible connector removably connecting the first and second panels.

In another embodiment, the connection system includes a first connector piece that is provided on the first panel and a second connector piece that is provided on the second panel, with the connector pieces removably connected to each other to removably connect the first and second panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The collapsible structures according to the present invention are configured in the form of one or more collapsible panels that are connected to each other by connectors. These structures can be folded and collapsed into a compact configuration for convenient storage and transportation.

FIG. 1illustrates a basic embodiment for a collapsible panel20. As explained in greater detail hereinbelow, the collapsible structures according to the present invention can each be comprised of one or more of these panels20assembled to create a resulting structure having the desired shape and size.

Referring toFIG. 1, the panel20is shown as having four sides, although it can have any number of sides and assume any desired size or shape. A continuous frame retaining sleeve22is provided along and traverses the periphery of the panel20. As shown inFIG. 2, a frame member24is retained or held within the frame retaining sleeve22to support the panel20. The frame member24may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop, or a strip of material having both ends unconnected but retained within the sleeve22. The frame member24is preferably formed of flexible coilable steel having a memory, although other materials such as plastics may also be used. The frame member24should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, the frame member24is capable of assuming two positions or orientations, an open or expanded position such as shown inFIG. 1, or a folded position in which the frame member24is collapsed into a size which is much smaller than its open position (seeFIG. 3E).

A fabric or sheet material26can be provided to extend across the panel20, and is held taut by the frame member24when in its open position. Fabric26can extend completely across the panel20to entirely cover the enclosed space defined by the frame member24, or can extend across selected portions of the enclosed space defined by the frame member24. The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric26should be water-resistant and durable to withstand wear and tear. The type of material used for the fabric26can be varied depending on the intended use.

Referring toFIG. 2, the fabric piece26is stitched at its edges by a stitching28to the sleeve22. The sleeve22may be formed by folding a piece of fabric, and then applying the stitching28to connect the sleeve22to the fabric26. Alternatively, the frame retaining sleeve22may be formed by merely folding over the fabric26and applying the stitching28. The frame member24may be merely retained within the frame retaining sleeve22without being connected thereto. Alternatively, the frame retaining sleeve22may be mechanically fastened, stitched, fused, or glued to the frame member24to retain it in position.

Amusement features can be provided on the panel20ofFIG. 1. For example, these amusement features can include indicia27such as a message, logo, or design that can be imprinted or otherwise provided on one or both sides of the fabric26, at any location thereon. Other amusement features, as illustrated in the other embodiments herein, can also be incorporated and provided on the panel20.

FIGS. 3A-3Edescribe the various steps for folding and collapsing the panel20ofFIG. 1for storage. InFIG. 3A, the first step consists of folding in the opposite borders of the panel20. As shown inFIGS. 3B-3D, the borders are folded in upon the previous fold to further collapse the frame member24with the panel20so that the initial size of the panel20is reduced.FIG. 3Eshows the frame member24and panel20collapsed on each other to provide for a small essentially compact configuration having a plurality of concentric frame members24and layers of the fabric26so that the collapsed panel has a size which is a fraction of the size of the initial panel20.

Each basic panel20can be used as a building block and combined with other basic panels to provide structures having different shapes and sizes, as illustrated below. The present invention discloses different connection systems that can be used for connecting panels20.

FIG. 1illustrates two connection systems according to the present invention. The first connection system comprises a button and hole combination where a button32is provided on the fabric26of one panel, and a button hole34is provided on the fabric26of another panel20, so that the button32can be inserted through the button hole34to effectuate the connection of the two panels20at the location of the button hole34. These buttons32and button holes34can be provided anywhere on the fabric26to facilitate connection at different locations, such as along the edge of the panel20, or in the middle of the panel20. The button connection allows the two connected panels20to be pivoted with respect to each other about the button32acting as a pivot point.

The second connection system comprises a zipper system where one panel has a connecting fabric40that has one edge stitched to an edge of the panel, and with its other edge having a zipper edge42, and a zipper44provided to travel along the zipper edge42. The other panel20can have a connecting fabric46that has one edge stitched to an edge of the panel20, and with its other edge having a zipper edge48. The panels can be connected by pulling the zipper44along the zipper edges42,48to connect the panels at the location of the connecting fabrics40,46. These connecting fabrics40,46can be provided anywhere on the fabric26to facilitate connection at different locations, such as along an edge of the panel20, or even in the middle of the panel20.

FIGS.1and4-6illustrate yet another connection system that can be used to connect a panel20to another panel20. First, connection holes or openings30can be provided in the fabric26and used in the manner to connect the panel20with a selected support piece50. These openings30can be provided anywhere on the fabric26to facilitate connection at different locations, such as along the edge of the panel20, or in the middle of the panel20.

The connection system further includes support pieces and connectors. An example of a support piece50is shown inFIG. 4, and examples of connectors52and54are shown inFIGS. 5 and 6, respectively. As explained in greater detail below, the support piece50can also be an interconnecting piece to interconnect two or more panels. Other examples of connectors and support pieces are illustrated in U.S. Pat. No. 6,116,981, whose entire disclosure is hereby incorporated by this reference as though set forth fully herein.

Each connector52,54and support piece50can be made from a material that is soft and flexible to allow it to be bent, folded or otherwise deformed, yet strong enough to allow the connections created from connections of such pieces to have structural stability. Examples of such materials include but are not limited to foam, polyethylene, polyurethane and PVC (expanded foam).

Referring toFIG. 4, the support piece50has a substantially rectangular body60, although the body60can be in any shape or size. The thickness of the body60is preferably consistent throughout. A plurality of apertures62are cut out or otherwise provided in the body60, and can be located at any location of the body60. InFIG. 4, the apertures62are shown as being provided in rows and columns so that any of these apertures62can be utilized for a connection. As shown inFIG. 1, the support piece50can be stitched, glued or otherwise secured to the panel20. Even thoughFIG. 1illustrates the support piece50as being secured to the fabric26, it can be secured at any location on the panel20.

Referring toFIG. 5, the connector52is adapted for use in connecting two panels20in a parallel manner. The connector52has an I-shaped body with a shaft66that has two deformable sections at opposite ends of the shaft66. Each deformable section is essentially comprised of ears68,70that extend perpendicular to the shaft66. Again, the thickness of the body is preferably consistent throughout.

Referring toFIG. 6, the connector54is adapted for use in connecting two panels20in a perpendicular manner. The connector54has a triangular-shaped body72with two generally T-shaped deformable sections74and76extending from adjacent right-angled edges78and80, respectively, of the body72. The thickness of the body72and sections74,76are preferably consistent throughout. The deformable section74has a shaft82that extends from the edge78, with two ears84extending perpendicular to the shaft82at an end the shaft82. Similarly, the deformable section76has a shaft86that extends from the edge80, with two ears88extending perpendicular to the shaft86at an end the shaft86.

The diameter of the apertures62should be about the same as the diameter of the openings30, and these openings30and apertures62, as well as the widths of the shafts66,82and86, should be sized and configured to allow the shafts66,82,86to extend through any of the openings30and apertures62. Also, the ears68,70,84and88should be sized and configured so that they can be bent or deformed to allow them to be squeezed through the openings30and apertures62.

FIGS. 7 and 8illustrate how the connection system ofFIGS. 4-6can be used to connect two panels.FIG. 7illustrates two panels20aand20b, each of which can have the same general construction as the panel20but with a different size and/or shape. A supporting piece50acan be secured to the panel20aat the location of a selected aperture62aand opening (not shown) on the panel20a, and another supporting piece50bcan be secured to the panel20b. The pieces50a,50bcan have the same general construction as the piece50but with a different size and/or shape. Another supporting piece50ccan be utilized as an interconnecting piece, with one connector52ainserted through a selected aperture62cin the piece50c, another aperture62ain the piece50a, and the opening in the fabric26aof the panel20a. Similarly, another connector52bis inserted through another selected aperture62cin the piece50c, another aperture62bin the piece50b, and the opening in the fabric26bof the panel20b. Thus, the interconnecting piece50cfunctions to connect the panels20aand20bin a side-by-side manner along the same plane.

FIG. 8illustrates two panels20dand20e, each of which can have the same general construction as the panel20but with a different size and/or shape. A supporting piece50dcan be secured to the panel20dat the location of a selected aperture62dand opening (not shown) on the panel20d, and another supporting piece50ecan be secured to the panel20eat the location of a selected aperture62eand opening (not shown) on the panel20e. The pieces50d,50ecan have the same general construction as the piece50but with a different size and/or shape. A connector54is used to connect the panels20d,20eat an orientation that is perpendicular to each other, with the shaft82and ears84inserted through a selected aperture62ein the piece50eand the opening in the fabric26eof the panel20e. Similarly, the shaft86and ears88can be inserted through a selected aperture62din the piece50dand the opening in the fabric26dof the panel20d.

FIG. 9further illustrates how the connection system ofFIGS. 4-6can be used with structures that are made up of a plurality of collapsible panels. The structure100shown inFIG. 9is comprised of a plurality of panels (e.g.,20g,20h,20i, among others) that are hingedly connected to each other in the manner described in U.S. Pat. No. 6,390,111 to form an enclosed space. The entire disclosure of U.S. Pat. No. 6,390,111 is hereby incorporated by this reference as though set forth fully herein. Another panel20fcan be connected to the panel20gusing the connection illustrated inFIG. 8using supporting pieces50d,50eand a connector54. In addition, an ornament102(such as a Christmas tree) that is made of a similar material as the connectors52,54and the supporting piece50can be removably attached to the panel20ivia a supporting piece50iand a connector52ithat can have the same construction as the piece50and the connector52, respectively. The shaft66and the ears68of the connector52ican be inserted through an aperture104in the ornament102, through a selected aperture62ion the piece50i, and through an opening (not shown) in the fabric26iof the panel20i.

FIG. 10illustrates modifications that can be made to the structure100ofFIG. 9. For example, the connector54alone can be used to connect the panels20fand20g, thereby omitting the supporting pieces50dand50e. In addition, other supporting pieces can be omitted so that only connectors (e.g.,52g) are used without the supporting pieces. As a further alternative, these connectors52gcan be fixedly attached to specific locations on any of the panels. For example, the connector52gcan be shaped as half the connector52inFIG. 5and attached (e.g., by glue, fusing, stitching) at the shaft66gto the fabric26gof the panel20g.

Thus, the present invention provides a system and method whereby a user can take a plurality of panels20, and through the use of any of the connection systems described above, can assemble a wide variety of different structures and objects. These panels20and connection systems form the basic building blocks for building a wide variety of objects. In addition, many of these connection systems are separate and removable so that the user can change the construction, shape and size of the object, and use the connection systems to add ornaments and other components and items.