Patent Document

FIELD OF THE INVENTION  
         [0001]    The present invention relates to a collapsible structure and, more particularly, to a collapsible structure including hinged walls which may be folded relative to one another for compactness or versatility. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0002]    [0002]FIG. 1A shows a collapsible structure in accordance with the invention, with dashed lines representing hinges.  
         [0003]    [0003]FIG. 1B shows the FIG. 1 structure in its collapsed form.  
         [0004]    [0004]FIG. 2A shows the FIG. 1 structure with its roof open.  
         [0005]    [0005]FIG. 2B shows the FIG. 1 structure with its roof assembled to form a gable roof style.  
         [0006]    [0006]FIG. 2C shows the FIG. 1 structure with its roof assembled to form a gambrel roof style.  
         [0007]    [0007]FIG. 3 shows the FIG. 1 structure with its roof open, and wall sections of the structure connected to roof sections of the structure.  
         [0008]    [0008]FIG. 4A shows the FIG. 1 structure configured with a gable roof with upper portions of end walls supporting the rake of the roof.  
         [0009]    [0009]FIG. 4B shows the FIG. 1 structure configured as a gambrel roof with upper portions of end walls supporting the rake of the roof.  
         [0010]    [0010]FIG. 5 shows the FIG. 1 structure in a partially collapsed condition, with the end walls and roof sections moved about their respective hinges, the roof sections and end walls being shown collapsed into respective storage positions.  
         [0011]    [0011]FIG. 6A shows the FIG. 1 structure further collapsed from the condition of FIG. 5, with the roof sections and end walls being further collapsed about their respective hinges.  
         [0012]    [0012]FIG. 6B shows the FIG. 1 structure further collapsed from the condition of FIG. 6A, whereby narrowly collapsed sections and pocket sections are formed due to the distance separating the hinges in the end walls and roof sections.  
         [0013]    [0013]FIG. 6C shows top, side and perspective views of the FIG. 1 structure in a final collapsed form and with the top view thereof showing the relative position of narrow sections nested within pockets formed by the collapsed structure.  
         [0014]    [0014]FIG. 7A shows a collapsible structure in accordance with the invention, with dashed lines representing hinges, the structure being shown with its roof open, the structure including an adjustable fastener including a tab and multiple slots which enable the structure to be assembled to have respective different length roofs.  
         [0015]    [0015]FIG. 7B shows a portion of the roof of the structure of FIG. 7A, with the tab inserted into a top-most slot, whereby the roof sections are configured to provide a full length roof.  
         [0016]    [0016]FIG. 7C shows a portion of the roof of the structure of FIG. 7A, with the tab inserted into a second slot, whereby the roof sections are configured to provide a roof of relatively shorter length than that of FIG. 7B.  
         [0017]    [0017]FIG. 7D shows a portion of a collapsible structure in accordance with the invention, with dashed lines representing hinges, the structure being shown with its roof open, the structure including an adjustable fastener including a tab and multiple slots which enable the structure to be assembled to have respective different length roofs.  
         [0018]    [0018]FIG. 8 shows different versions of blanks in accordance with the invention that can be used to create respective collapsible structures.  
         [0019]    [0019]FIG. 9 shows a single blank in accordance with the invention, such blank being connectable to form a collapsible structure in accordance with the invention, the blank including end walls, side walls with connected roof sections, hinges for configuring the structure as a gable or gambrel roof, adjustable tab/multiple slot fastening means, hinges for creating pockets and narrowly collapsible sections that nest within the pockets.  
         [0020]    [0020]FIG. 10 shows two identical blanks in accordance with the invention, such blanks being connectable to form a collapsible structure in accordance with the invention, the blanks together including end walls, side walls with connected roof sections, hinges for configuring the structure as a gable or gambrel roof, adjustable tab/multiple slot fastening means, hinges for creating pockets and narrowly collapsible sections that nest within the pockets.  
         [0021]    [0021]FIG. 11 shows two different blanks in accordance with the invention, such blanks being connectable to form a collapsible structure in accordance with the invention, the blanks together including end walls, side walls with connected roof sections, hinges for configuring the structure as a gable or gambrel roof, adjustable tab/multiple slot fastening means, hinges for creating pockets and narrowly collapsible sections that nest within the pockets.  
         [0022]    [0022]FIG. 12 shows four blanks in accordance with the invention, such blanks being connectable to form a collapsible structure in accordance with the invention, the blanks together including end walls, side walls with connected roof sections, hinges for configuring the structure as a gable or gambrel roof, adjustable tab/multiple slot fastening means, hinges for creating pockets and narrowly collapsible sections that nest within the pockets.  
         [0023]    [0023]FIG. 13 shows two identical blanks connected together to create a collapsible structure in accordance with the invention, the collapsible structure being shown in a partially collapsed condition.  
         [0024]    [0024]FIG. 14A shows the collapsible structure of FIG. 13, the structure including the blanks of FIG. 13 positioned so that the end-walls are parallel to each other and perpendicular to the side-walls, wherein dashed lines represent hinges, and wherein the structure is shown with its roof open.  
         [0025]    [0025]FIG. 14B shows the FIG. 14A structure in a partially collapsed condition, with the end walls and roof sections moved about their respective hinges, the assembled blanks&#39; roof sections and end walls collapsed into respective storage positions.  
         [0026]    [0026]FIG. 14C shows the FIG. 14A structure further collapsed from the condition of FIG. 14B, with the roof sections and end walls being further collapsed about their respective hinges.  
         [0027]    [0027]FIG. 14D shows the FIG. 14A structure further collapsed from the condition of FIG. 14C, whereby narrowly collapsed sections and pocket sections are formed due to the distance separating the hinges in the end walls and roof sections.  
         [0028]    [0028]FIG. 14E shows the structure completely collapsed. FIG. 14E shows a perspective view of the FIG. 14A structure in a final collapsed form.  
         [0029]    [0029]FIG. 15A shows multiple views of the collapsible structure being sequentially expanded from its final collapsed condition on the left to a partially expanded condition on the right.  
         [0030]    [0030]FIG. 15B shows the hinges used to configure the expanded structure&#39;s end walls so they will fit and support either a gable or gambrel roof line.  
         [0031]    [0031]FIG. 15C shows the structure&#39;s roof sections being configured as a gable roof and fastened using the tab/multiple slot design.  
         [0032]    [0032]FIG. 15D shows the structure&#39;s roof sections being configured as a gambrel style and fastened using the tab/multiple slot method.  
         [0033]    [0033]FIG. 16A shows a collapsible structure in accordance with the invention, with dashed lines representing hinges, the structure being shown with its roof assembled to form a gable roof style.  
         [0034]    [0034]FIG. 16B shows a collapsible structure in accordance with the invention, with dashed lines representing hinges, the structure being shown with its roof assembled to form a gambrel roof style.  
         [0035]    FIGS.  16 C- 16 G sequential views of the FIG. 16A collapsible structure or the FIG. 16B collapsible structure being collapsed to FIG. 16C by disconnecting the roof sections and end walls, further collapsed to FIG. 16D by positioning the end walls and roof sections into their respective storage positions, further collapsed to FIG. 16E by compressing together the end walls and bending the side wall/roof sections along their respective hinges, further collapsed to FIG. 16F by forming the pockets and narrowly collapsed sections, and further collapsed to FIG. 16G by compressing the structure to the final collapsed form. 
     
    
     DETAILED DESCRIPTION  
       [0036]    [0036]FIG. 1A shows a collapsible structure in accordance with the present invention. The collapsible structure easily collapses to a significantly smaller collapsed form, for example, as shown in FIG. 1B. This is accomplished by providing hinges  10  between sections  12  which, when the sections are bent about the hinges  10 , create a pocket  11  between the hinges  10  (illustrated in FIG. 1B) to accommodate narrower sections collapsed about a hinge  14 .  
         [0037]    The collapsible structure is capable of being erected to have different roof styles. The roof is shown open in FIG. 2A. The roof may be assembled to have a gable style, as shown in FIG. 2B or a gambrel style, as shown in FIG. 2C. This is accomplished by configuring the end wall  18  that supports the roof panels  30 ,  32 .  
         [0038]    Since the end wall panel  18  is of a fixed height, the linear distance between the peak of the roof and tops of the side walls and, accordingly, the surface area of the roof will decrease as the upper portions of the panels are reconfigured from a gambrel FIG. 2C to gable FIG. 2B roof. The roof panels  30 ,  32  have hinges  34  and  36  to enable the roof panels length to be adjusted accordingly. Hinge  38  enables the roof sections to be straight for a gable configuration FIG. 2B or bent for a gambrel FIG. 2C roof-line. The roof panels  30 ,  32  can also include additional hinges  40  which when bent increase the structural integrity of the roof as well as serve as a means for applying fastening means if so desired.  
         [0039]    The upper portions  20  of the end walls  18  have multiple hinges. Hinges  22  and  24  may be used to create a gable roof line. Alternatively hinges  26 ,  27 ,  28 , and  29  may be used to create the gambrel roof line. The upper portion of end wall opposite to the upper portion  20  of end wall  18  has the same hinge configuration to support the other end of roof panels  30 ,  32 .  
         [0040]    The structure can be manufactured from a variety of materials either plain or laminated or finished such as wood, steel, fiberboard, plastic, fabric covered frame, coated material, for example, dry erase style surface and waterproofing.  
         [0041]    Although the invention is described chiefly as a collapsible playhouse structure it will be appreciated by those skilled in the art that the invention may be used for creating other collapsible structures such as temporary shelters, animal shelters, theaters, playhouses, greeting cards and advertising displays.  
         [0042]    [0042]FIG. 3 shows a collapsible, foldable playhouse structure including wall panels  12 ,  18 ,  42 ,  48  that are connected to each other and roof panels  30 ,  32  which are connected to the wall panels  12  and  42 . The completed collapsible playhouse structures shown in FIG. 4A and FIG. 4B show the upper portions  20 ,  50  of the two end walls  18 ,  48  lend support to two roof panels  30 ,  32 . The roof  30 ,  32  and end walls  18 / 20 ,  48 / 50  are held in the expanded ready-for-use position by suitable fastening means, for example, glue, interlocking tabs and slots, and staples. The two side roof panels  30 , 32  connect at the peak with interlocking tabs and or other suitable fastening means. The collapsible playhouse structure may be collapsed as shown in FIG. 5 by folding the roof panels  30 ,  32  outward to rest against the outside surface of the wall panels  12 ,  42 . The upper portion of the end wall panels  20 ,  50  may be folded either inward or outward so that they rest flat against respective lower portions of the end wall panels  18 ,  48 . FIG. 6A illustrates how the roof/wall portions  30 / 12 ,  32 / 42  and end wall portions  18 / 20 ,  48 / 50  are then folded along hinges  10  and hinges  14  to create collapsing sections. FIG. 6B illustrates how a distance that accommodates the total thickness of one or more panels collapsing about hinges  14  separates the hinges  10  that create the pockets  11 . FIG. 6C illustrates the natural nesting of the collapsing sections  14  within the pockets  11  upon further collapse of the structure.  
         [0043]    A simple, releasable and reusable fastening device, which can accommodate changes in mating panels length, can be made an integral part a panel.  
         [0044]    The adjustable fastening device may be implemented to secure the playhouse roof panels as they are increased or decreased in length due to the configuration as a gambrel or gable roof. FIG. 7A illustrates an adjustable fastening means including multiple slots  52 ,  54  and a single tab  56  serving to fasten the roof panels  30 ,  32 . When the roof panel is utilized at the maximum length FIG. 7B, tab  56  is inserted into slot  52 . As the roof length is decreased FIG. 7C the tab is inserted into slot  54 . Additional slots  55  can be added below slot  54  as needed to accommodate further decreases of panel lengths FIG. 7D.  
         [0045]    [0045]FIG. 8 illustrates how the design can be implemented using a single blank  60 , two identical blanks  61 ,  62 , two different blanks  63 ,  64 , or multiple blanks  65 ,  66 ,  67 ,  68  each representing a section of the structure. For instance, a single blank FIG. 9 may include all north  70 , south  72 , east  74 , west walls  76  and the roof panels  78 ,  80 . Two identical blanks FIG. 10 may include two walls  82 ,  84  and one roof panel  86 . Two different blanks FIG. 11 may include two walls and one roof panel but the two walls  90 ,  92  and roof panel  94  in one blank are different in structure as shown from the two walls  91 ,  93  and roof panel  95  of the second blank. Four blanks FIG. 12 where each blank contains a quadrant  100 ,  102 ,  104 ,  106  of the structure as shown and may have various or identical structure.  
         [0046]    The blanks may be fastened by any suitable means for example glue, nails, tape, staples, tabs, either at the time of manufacture or assembly by the end user.  
         [0047]    In an exemplary embodiment, two identical blanks of cardboard are glued to each other at the ends to create a collapsible play structure. Fastening the blanks at the time of manufacture reduces the end user assembly or disassembly time, effort, physical ability, and skill level requirements.  
         [0048]    The identical blanks have integral glue tabs which when fastened form hinges and score lines to create the remaining hinges. First the blanks are folded FIG. 13 to enable the glue tab  110  of blank A  112  to overlap the end of blank B  114  and vice versa. After the glue tabs are secured the structure is opened so that the end walls  18 , 48  are parallel and side walls  12 ,  42  are parallel FIG. 14A. The roof panels  30 ,  32  and upper portions  20 ,  50  of the end walls  18 ,  48  are folded into respective storage positions FIG. 14B. FIG. 14C shows the collapsed sections are then folded along the hinges  14 ,  10  to form the narrow collapsed sections and pocket sections illustrated in FIG. 14D. The structure FIG. 14E is now collapsed and ready for shipment.  
         [0049]    The collapsed structure is easily setup using minimal folding motions followed by completion of a suitable fastening means. As the structure in FIG. 15A is expanded like an accordion the collapsed sections  100  escape from the pockets  102 . FIG. 15B illustrates how the upper portions  105 ,  107  of the end walls  104 ,  106  are flipped up into position and configured for the desired roof style by using hinges  120 ,  121 ,  122 ,  123  for a gable roof line. Alternatively hinges  130 ,  131 ,  132 ,  133 ,  134 ,  135 ,  136 ,  137  are used for a gambrel roof line. FIG. 15C shows how the roof panels  140 ,  141  are flipped up into position and configured for gable configuration by using hinges  142 ,  143 ,  144 ,  145  or alternatively FIG. 15D shows the use of hinges  150 ,  151  for a gambrel roof line. The roof panels are connected to the end wall via suitable means. Roof panel  140  is secured to roof panel  141  via suitable fastening means, for example, by means of tabs as illustrated in FIG. 15C and FIG. 15D. The structure is now ready for use.  
         [0050]    [0050]FIG. 16 illustrates how the structure is collapsed from either the gable configuration FIG. 16A or gambrel configuration  16 B to the final form  16 G, by removing the securing devices between roof panel  140  and roof panel  141 . Then as shown in FIG. 16C separate the roof panels  140 ,  141  from the upper portions  105 ,  107  of the end wall panels  104 ,  106 . As shown in FIG. 16D bring the roof panels  140 ,  141  to rest against the outside of attached walls  152 ,  153 . Return the upper portions  105 ,  107  of the end wall to rest against the lower portions  104 ,  106  of the end walls. FIG. 16E shows how to fold the remaining side wall/roof sections  140 / 152 ,  141 / 153  and end wall upper/lower sections  105 / 104 ,  107 / 106  along the hinges  170  thereby creating collapsed sections  180  and hinges  172  creating pocket sections  182  as shown in FIG. 16F. Finish by nesting the collapsed sections  180  into the pocket sections  182 . The structure is now in the collapsed configuration of FIG. 16G and ready for storage or shipment.

Technology Category: b