Patent Publication Number: US-7592053-B2

Title: Ornamental figure construction kit

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application claims priority to U.S. provisional application Ser. No. 60/512,558, filed on Oct. 17, 2003, incorporated herein by reference. 

   BACKGROUND 
   1. Technical Field 
   This invention is in the field of ornamental figures for lawns and gardens and, in particular, relates to apparatus for constructing such figures. 
   2. Background 
   Ornamental figures for lawns and gardens are quite popular, especially in warmer climates. Mass produced items are made from plastic. Plaster of Paris figures from molds are also popular. Wire frames have been used with a fabric or other covering. Even decorated plastic bags filled with tree leaves are used for construction of Halloween figures in the U.S. 
   Another construction material is flower pots or clay pots. These are readily available, relatively inexpensive starting materials, ideally suited for weathering outdoor elements. Moreover, they are esthetically suitable for lawn and garden settings. 
   A search on the Internet for “clay pot people” turned up about 157,000 results. This includes people making clay pots. A quick perusal of the first few results indicated that there was great interest, both amateur and commercial, in using clay pots for figures and other ornamental designs. However, it appeared that the majority decorated a single pot. Occasionally a stack of two clay pots, the one on the bottom being inverted, was used. No one seemed to have attempted using a larger number of pots. 
   Problems with using a large number of clay pots are that a nested stack would use too many pots per unit of height and stacks with pots rim-to-rim would be unstable. Thus, until this invention, people have been limited to using one or two clay pots to produce ornamental figures. 
   An apparatus that would allow the use of a number of clay pots would be a boon to lawn and garden ornamental design. However, to be a practical success, such apparatus must be very inexpensive and simple to assemble. Mechanically, it must be light, yet strong enough to support clay pots. It should be neither so rigid that pots cannot be oriented at different angles nor so flexible that pots are oriented solely by gravity. To save costs, there should be as few different parts as possible. Of course, it should not have sharp points, edges, or rough areas. Although it is not essential to meet all of these goals to practice the invention, each is desirable. So far, however, there is nothing available on the market to meet even the overall need. 
   SUMMARY 
   The objectives of the invention are realized with a kit of parts comprising a plurality of elongated structures having a plurality of article stop restraints, at least one locking structure, and at least one lock engagement and a plurality of construction article stops mountable on the article stop restraints on the elongated structures. 
   In particular, the elongated structures can be plastic rods about 18 inches long and 3/16 inch diameter having ⅜ inch diameter spherical enlargements at 2¾ inch intervals. At one end of the rods, there is a plate having an aperture with a clearance hole for the spherical enlargements and a passageway to a locking hole that admits the rods, but is too small for the spherical enlargements. The article stops can be made from discs about 1¼ inch diameter and ⅛ inch thick having a slot to the center that is wide enough for the rods but too narrow for the spherical enlargements. Thus, when the discs are mounted on a rod, the spherical enlargements restrain the discs from moving in one direction. The construction articles can be, for example, clay pots or other similar articles having a hole in the bottom larger than the rods but smaller than the discs. 
   A spherical enlargement on the end of one rod can engage the locking structure on the end of another rod so that a 36 inch composite rod can be formed from two 18 inch rods. (Except where noted below, most dimensions are approximate and provided as aids to visualization only and are not a limitation on the invention.) 

   
     DESCRIPTION OF THE FIGURES 
     The features and advantages of the invention will now be described in more detail with a detailed description making reference to the following appended drawings: 
       FIG. 1  illustrates the invention being used to construct an ornamental figure from a variety of sizes of clay pots assembled from a kit of rods and discs; 
       FIG. 2   a  shows a top view of one of the rods in  FIG. 1  having spherical enlargements and an end plate; 
       FIG. 2   b  shows a side view of the rod in  FIG. 2   a;    
       FIG. 2   c  shows an enlargement of the end plate in  FIG. 2   a;    
       FIG. 3   a  shows a top view of one of the discs in  FIG. 1 ; 
       FIG. 3   b  shows a side view of the disc in  FIG. 3   a;    
       FIG. 4   a  shows a side view of two rods and a disc in a “ball-to-plate” locked engagement; and 
       FIG. 4   b  shows a side view of two rods and a disc in a “plate-to-plate” locked engagement. 
   

   DETAILED DESCRIPTION 
   Working Example 
     FIG. 1  illustrates a working example of the invention. In this example, an ornamental  figure 10  that simulates a human figure was constructed from common flower pots. The figure is shown with various cross-sections sitting on a chair  20 . It comprised arms  12  and legs  14 , one each of which is shown, and a head  16  on a torso  18 . 
   The arms comprised a plurality of pots  12   p  held together by the structure  12   s.  In the working example, each arm used six 4 inch diameter clay pots. Likewise, the legs were formed from a plurality of pots  14   p  held up by the structure  14   s.  Each leg used eight 6 inch diameter clay pots. The torso was comprised of a lower pot  18   l  and an upper pot  18   u  with support structure  18   s  on which a single pot  16   p  is the head, held in place by the structure  16   s.  The working example used 10 inch diameter pots for the torso and an 8 inch diameter pot for the head. 
   As partially illustrated, the leg support structures  14   s  wrapped around the back of the bottom torso pot  18   l  and connected to each other using rod  14   c.  The arm support structures  12   s  were connected via a gap between the upper torso pot  18   u  and head pot  16   p.  The chair  20  had a hole  20   h  that was used to anchor the  figure 10 . 
   The various support structures in  FIG. 1  were made from plastic rods and discs as illustrated in  FIGS. 2 &amp; 3 .  FIG. 2   a  shows a top view of rods  30  with dimensions in inches and  FIG. 2   b  shows a side view. The rods have a plurality of equal-size, spherical enlargements or balls  32   a - 32   g  that are mechanically connected with respective bars  34   a - 32   g.  One end of the rod is terminated in a flat end plate  36 . Note that the end plate  36  joins the approximate bottom (as illustrated) half of the rod bar  34   g.  The balls  32   b - 32   g  are equally spaced in the working example, but the end ball  32   a  is closer to the next ball  32   b  than the spacing between the other balls. 
     FIG. 2   c  illustrates the end plate  36  in more detail. This plate has an aperture comprising a larger clearance hole  36   c  and a smaller locking hole  36   l that are connected by a passage  36   w . The diameter of the clearance hole  36   c  is approximately the same as the diameter of the balls  32   a -  32   g  and the diameter of the locking hole  36   l is approximately the same as the diameter of the bars  34   a - 34   g . However, a portion of the width of the passageway  36   w  is slightly less than the diameter of the bars. Note that the overall 0.622 inch width (which can be inferred from the other dimensions) of an end plate  36  is enough less than the 0.675 inch distance (also inferable) between the extremes of hole  36   c  and  36   l so that one end plate can pass through another. (This is an example of more critical dimensions, namely, for use as a locking engagement, the width of a plate  36  be less than the aperture inside one. Other examples should be obvious to those skilled in the relevant arts and will not be pointed out.) 
     FIG. 3   a  is a top view and  FIG. 3   b  is a side view of the discs  40  used in the construction of the  figure 10 . In the working example, these have a diameter of 1.250 inches with a central hole  40   h  and a slot-like passageway  40   w  to the circumference. The diameter of the hole  40   h  is approximately the same as the diameter of the bars  34   a - 34   g.  However, a portion of the width of the passageway  40   w  is slightly less than the diameter of the bars. The 0.625 inch radius of a disc  40  is approximately the same as the distance from the center of a locking hole  36   l  of an end plate  36  to its juncture with a bar  34   g.  The significance of this will become apparent below. The 0.125 inch thickness of the discs  40  allows them to nest on top of end plates  36 . 
   In the working example, the rods  30  and discs  40  were made from injection-molded polypropylene using a well know cold runner mold process. The polypropylene was a mixture of 70% virgin material and 30% reground scrap. This produced low cost, strong, tough, yet flexible parts. The working example rods are flexible enough to be manually bent into a complete circle. It is well know that up to 50% reground scrap can be used with not much effect on material properties. An appliance white colorant was used with a UV-oxidation inhibitor for outdoor use. In larger scale production, a hot manifold process would be preferable. It is believed that making and modifying the injection molding process for the invention would be routine for those skilled in the art of plastics manufacture. 
   The working example illustrated in  FIG. 1  used 9 rods  30  and 35 disks  40  for construction of the supporting structures. Using the discs  40 , the rods can be assembled together in two ways, hereinafter designated as a “ball-to-plate connection” or a “plate-to-plate connection” to make an extended rod. A third method of assembly, useful in come cases, is to simply pass a rod through the clearance hole  36   c  in one or more rod end plates  36 . 
     FIG. 4   a  illustrates a ball-to-plate connection between two rods  30 - 1  and  30 - 2 . The end ball  32   a  of a rod  30 - 2  is inserted through the clearance hole  36   c  of a rod  30 - 1  and the bar  32   a  is pushed through the passageway  36   w  into the locking hole  36   l.  In the working example, moving the bar  34   a  through the passageway  36   w  requires moderate hand pressure and results in an audible snap. A disc  40  is then inserted over the bar  34   a  of rod  30 - 2  between the end ball  32   a  of rod  30 - 2  and plate  36  of rod  30 - 1  until bar  34   a  is located in the hole  40   h.  This also requires moderate hand pressure and results in an audible snap. Hereinafter, “snap” will be used as a verb meaning to push a disc  40  over a bar  34   a - 34   g  until the bar is located in the hole  40   h.    
   Note that the disc  40  is rotated until its slot  40   w  is directed away from the rod  30 - 1 . With the dimensions in the working example, the disc  40  is nested against the end plate  36  butting against the bar  34   g  of the rod. When tension is applied to rods  30 - 1  and  30 - 2 , even though they bend, end ball  32   a  and plate  36  press on disc  40  and lock it into position against bar  34   g.    
   In some situations, a disc  40  is not required. If the rods  30  are put under enough opposing tension before being rotated, the ball  32   a  will not rotate out through clearance hole  36   c,  but will be locked into hole  36   l.  Usually, however, it will be convenient to use a disc  40 . 
   The reason for the lesser spacing of end ball  32   a  and from ball  32   b  is to provide approximately constant ball spacing across two connected rods. When the rods  30 - 1  and  30 - 2  are pulled under tension and rotated into an approximate straight line, the distance between ball  32   g  on rod  30 - 1  and ball  32   b  on rod  30 - 2  is approximately the same as the distance between other balls that do not take part in connections. 
     FIG. 4   b  illustrates the second way to make an extended rod. In this, the end plate  36  of a rod  30 - 2  is inserted through the end plate  36  of rod  30 - 1  and pushed into the locking hole  36   l  of rod  30 - 2 . Once the rod  30 - 2  is rotated 90 degrees, there is little tendency for its end plate to pull through under tension because, unlike an end ball, it is too wide to be rotated out. 
   For more security, a disc  40  can be snapped onto bar  34   g  of rod  30 - 2  between plate  36  of rod  30 - 1  and plate  36  of rod  30 - 2 . As in the ball-to-plate connection, the disc  40  is rotated until its slot is directed away from the rod  30 - 1 . Also, preferably, the end plate  36  of rod  30 - 2  is directed away from rod  30 - 1 . With these orientations, disc  40  fits more securely against both flat plates. When the rods are under tension, there is no tendency for them to break free. 
   One method for assembling the ornamental figure in  FIG. 1  will now be described. First, it should be noted that, if clay pots are used, consideration must be given to the fact that they are not particularly light. A leg formed from eight 6 inch clay pots can weigh about 13 pounds. Nonetheless, the method give below has been feasible for most people. 
   First, the ornamental figure in  FIG. 1  will require the kit of 9 rods  30  and 35 discs  40  plus, as shown, 12 pots—4 inch diameter, 16 pots—6 inch diameter, 1 pot—8 inch diameter, 2 pots—10 inch diameter, and a chair. It is preferable that, at least the larger three pot sizes pots have drain holes in the bottom large enough to pass the rod end plates  36 , but small enough to stop the discs  40 . For clay flower pots, this is commonly the case for these three sizes. However, 4 inch diameter pots have drainage holes that are large enough to pass the balls  32  on the rods  30 , but are too small to pass the end plates  36  and require a modified construction technique. 
   The figure shown in  FIG. 1  has been built, but the process will be described in the present tense. As noted previously, there are many interchangeable parts and different reference numerals will not be used for the same part used in different locations. 
   The first step is to mount the torso  18  on the chair  20 . Chairs with existing holes through the seat, such as wicker or metal mesh, may be used. If a chair with a solid base is used, a 10 inch pot should be positioned in the chair as desired. Positioning toward the back would make it possible to put a potted plant or other addition between the legs of the figure. After marking the drain hole position, the pot should be removed and a hole of about 0.375 inch diameter drilled through the chair seat. Then, replace the 10 inch pot  18   l.  Insert a rod  30  through the pot and chair hole  20   h  until a ball  32   b  and bar  34   b  protrude. Snap a disc  40  over bar  34   b  so that it cannot be pulled through the hole. Using a second rod  30 , make a ball-to-plate connection to the first rod  30 . Slip the end plate  36  of the second rod  30  through the drain hole in a second 10 inch pot  18   u,  oriented upside down as shown in  FIG. 1 . Snap a disc over the second rod  30  on the outside of the pot  18   u.  This completes the torso. 
   The legs  14  are built as a vertical stack and then attached to the torso  18 . The number of pots required may vary with the height of the chair. Using two connected rods  30 , as many as eleven pots can be equally spaced in a stack.  FIG. 1  illustrates an eight pot stack. This is obtained by cutting a rod  30 , below its ball  32   f.  (With the plastic rods in the working example, either a saw or sturdy wire cutter is adequate.) Then, snap a disc  40  over the bar  32   f.  Slide the rod through the drain hole in an inverted 8 inch pot. Snap a disc over bar  32   g  and slide the rod through a second 8 inch pot. Then, make a ball-to-end connection with a second rod  30 . Snap a disc over bar  32   b  of the second rod and add a third pot. Continue until an eighth pot is added at the disc snapped over bar  32   g  of the second rod  30 . Repeat the process for a second leg  14 . 
   The legs  14  may be secured to the torso  18  using a connecting rod  14   c  between the legs. After positioning the legs where desired, make a ball-to-plate connection to one leg and wrap rod  14   c  around the torso pot  18   l,  as illustrated in  FIG. 1 . Then make a plate-to-plate connection to the other leg (not shown). If rod  14   c  is too long, a rod-to-plate connection can be made using one of the intermediate balls  34   b - 32   g.  If one rod is not long enough, two rods can be used to make a longer connection  14   c.    
   For the arms  12 , as illustrated in  FIG. 1 , 6 pots are used. Because drain holes for common 4 inch diameter clay pots are too small for the end plate  36 , the procedure for the arms is slightly different; the arms are built from the top down. It may be convenient to lay the pots on their sides. Slide a first rod  30 , ball end first, through a first pot until the end plate  36  and ball  32   g  protrude from the bottom. (The extra length will be used later.) Reach inside the first pot and snap a disc over bar  32   f.  Next, slide a second pot, bottom side first, up the rod as far as possible. Reach inside the second pot and snap a disc over bar  32   e.  Similarly, slide on four more pots and sequentially snap four more discs over bars  32   d,    32   c,    32   b,  and  32   a.  In a similar manner make a second arm. 
   When the two arms are finished, rods with bar sections  32   f  and  32   g  and endplates  36  should be protruding from the top pots. These two endplates are then slipped over the head support bar  16   s  protruding through the torso pot  18   u.  Then, head pot  16   p  is slipped over support  16   s  down onto arm supports  12   s  to help anchor the arms  12 . One or more discs  40  (one is illustrated in  FIG. 1 ) are snapped onto support  16   s  inside the head pot  16   p  near its inside bottom to keep it stable. 
   The basic figure can now be decorated in any number of ways. For example, a fern plant can be added to the head pot  16   p  to simulate hair. 
   The invention is not limited to making clay pot figures. Using the kit of rods and discs, one can make a variety of figures and ornamental designs including boats, flowers, spider webs, dragonflies, etc. These need not be located outside. 
   Other Equivalent Variations 
   Although the invention was described with reference to a working example, it should be clear to those skilled in the art that the invention is not limited to the particular method of making the support structures. The dimensions shown in the drawings are a typical example of what appeared to be suitable for clay pots of the sizes used in the working example. There could be a redundant number of spherical enlargements to accommodate more different sizes. 
   With respect to the rods  30 , they need not be exactly as described. The enlargements  32  need not be spherical, but could be cylinders, cones, ellipsoids, or even some ornamental shape. Likewise, the bars  34  need not have a circular cross section. Oval, square, rectangular, or even fanciful ones could be used. Although the rods should not be so rigid that they can&#39;t be bent, they should be at least strong enough to be self supporting. The rigidity exhibited by the plastic rods in the working example appears to be a good compromise. This requirement excludes strings, ropes, chains and the like. 
   Instead of enlargements, the rods could have short segments (e.g., 0.125 inches long to match the width of discs  40 ) of reduced diameter or width. These short segments would have a diameter or width to match the width of slot  40   s.  The last segment would not be useable unless there was a short segment of a larger bar  34  on the end. This approach means that the discs  40  are restrained from moving in both directions along the rods  30 . However, for the rods to have the same tensile strength, the reduced size segments would have to be created by making the size of the bars larger. Whatever the design, the functionally requirement is for a plurality of disc restraints operative in at least one direction. Along the same line, two enlargements could be positioned a short distance apart so that two discs or the equivalent could be located between them with enough spacing to admit a pot or other article and constrain it from moving in both directions. 
   The flat end plates  36  need not be flat or on the end of a rod  30 . An intermediate enlarged segment having an aperture with a clearance hole and a passageway to a smaller locking hole would work as a locking structure. In the case where reduced size segments replace enlargements, the clearance hole would be large enough to clear the bars  34  and the locking hole large enough to accommodate a short segment but not large enough to clear a bar. 
   The clearance hole  36   c  need not be a hole. Although mechanically weaker, an L-shaped slot could be used on one side of the locking structure  36  with an entrance wide enough for the bars  34  and a passageway to a locking hole. If reduced size segments are used on the rods, they would be locked in both directions. Even with enlargements, a more complicated locking structure could lock the rods in both directions. The functional requirement for the locking structure is that it has clearance for the rods with passage to a locking area that is effective to restrain some locking engagement structure on the rods in at least one direction. 
   The location of locking structure  36  could be intermediate on the rod  30  between enlargements  32 . In that case, ball-to-plate connections or the equivalent could be made at both ends of the rods. 
   The discs  40  need not be circular plates; they could be squares, rectangles, stars, or three dimensional shapes with slots cut sufficiently deep. The slots  40   w  could be of a uniform width and rely on friction to hold them in place on a bar  34 . Instead of a slot from the side, an aperture similar to the one in the plate  36  could be used. A double disc structure with a connection opposite the slots could be used to surround the enlargements  32  and prevent movement in both directions along the rod  30 . Functionally, these structures, hereinafter, “article stops,” must be mountable on the rods and sized to stop a pot or other construction article from movement along the rods in at least one direction. 
   It is convenient to use the same features on the rods to restrain the article stops and engage the locking mechanism, but this is not essential. Different shapes could be used to operate as locking engagements and restrain article stops. 
   To summarize, the rods  30  with bars  34  are an example of an elongated structure, the balls  32  are an example of an article stop restraint and/or lock engagement, the end plate  36  is an example of a locking structure, and the discs  40  are examples of construction article stops. 
   Lastly, the invention is not limited to using clay pots or even flower pots. It would be useful for just about any construction articles that have a shape that allows nesting. An example would be plastic cones with a hole at the apex. The minimal requirement is that the articles have a hole on one end smaller than an article stop and a hole on another end larger than an article stop.