WALL STRUCTURE

Abstract

A wall structure, comprising a panel having first and second sides, wherein the first side has a generally flat surface and the second side defines a corrugated surface, wherein the panel defines a plurality of holes; and a pliable material disposed on the corrugated surface of the second side.

Claims

1. A wall structure, comprising: a panel having first and second sides, wherein the first side has a generally flat surface and the second side defines a corrugated surface, wherein the panel defines a plurality of holes; and a pliable material disposed on the corrugated surface of the second side.

2. The wall structure of claim 1, wherein the pliable material covers the entire second side.

3. The wall structure of claim 1, wherein the pliable material comprises dough.

4. A method for making a decorative structure, comprising: providing an enclosed three-dimensional primary support structure having three or more sides and/or portions; wherein the primary support structure has a plurality of primary support structure tabs, wherein each of the plurality of primary support structure tabs is disposed on or integral with a respective one of the sides and/or portions; wherein the primary support structure has a plurality of primary support structure slots; wherein each of the plurality of primary support structure slots is defined by one of the sides and/or portions; wherein the primary support structure has a plurality of panel tab receiving slots; wherein each of the panel tab receiving slots is defined by one of the sides or portions; inserting each of the plurality of primary support structure tabs into a corresponding one of the plurality of primary support structure slots to assemble three-dimensional primary support structure; providing a plurality of panels wherein each of the plurality of panels (a) defines a plurality of holes, (b) corresponds to a respective one of the sides and/or portions of the primary support structure and (c) has a panel body consisting essentially of (i) a sheet of material having a front side and a back side; wherein the front side has a corrugated surface adapted to receive a pliable material; and (ii) one or more panel tabs integral with or attached to a perimeter of the panel body; applying a pliable material to the corrugated surface of each of the plurality of panels; baking each of the plurality of panels with the applied pliable material; installing the plurality of baked panels onto the primary support structure by inserting the one or more panel tabs of each panel into a respective one of the plurality of panel tab receiving slots in the primary support structure.

5. The method of claim 4, wherein the three-dimensional primary support structure defines a house and each of the sides and/or portions of the primary support structure comprises part of the house.

6. The method of claim 4, wherein the three-dimensional primary support structure defines an item selected from the group consisting of a house, a ship; an ark; a basket; a tree; a plaque; a sign; a menu; a cake; a car; a trucks, a city; a gift box; a castle; a volcano; a tee pee; a draidel; a wagon; a window box; a wishing well; a graduation cap; a baby block; a train; a church; a carousel; a log cabin; an animal; a space ship; a carry-out food box; a cradle; a book; a pyramid; and a treasure chest and wherein each of the sides and/or portions of the primary support structure comprises part of the item.

7. The method of claim 4, wherein the pliable material comprises dough.

8. The method of claim 4, wherein the pliable material comprises gingerbread dough.

9. A kit for making a decorative structure, comprising: an enclosed three-dimensional primary support structure having three or more sides and/or portions; wherein the primary support structure has a plurality of primary support structure tabs, wherein each of the plurality of primary support structure tabs is disposed on or integral with a respective one of the sides and/or portions; wherein the primary support structure has a plurality of primary support structure slots; wherein each of the plurality of primary support structure slots is defined by one of the sides and/or portions; wherein the primary support structure has a plurality of panel tab receiving slots; wherein each of the panel tab receiving slots is defined by one of the sides or portions; a plurality of panels wherein each of the plurality of panels (a) defines a plurality of holes, (b) corresponds to a respective one of the sides and/or portions of the primary support structure and (c) has a panel body consisting essentially of (i) a sheet of material having a front side and a back side; wherein the front side has a corrugated surface adapted to receive a pliable material; and (ii) one or more panel tabs integral with or attached to a perimeter of the panel body.

10. The kit of claim 9, wherein the three-dimensional primary support structure defines a house and each of the sides and/or portions of the primary support structure comprises part of the house.

11. The kit of claim 9, wherein the three-dimensional primary support structure defines an item selected from the group consisting of a house, a ship; an ark; a basket; a tree; a plaque; a sign; a menu; a cake; a car; a trucks, a city; a gift box; a castle; a volcano; a tee pee; a draidel; a wagon; a window box; a wishing well; a graduation cap; a baby block; a train; a church; a carousel; a log cabin; an animal; a space ship; a carry-out food box; a cradle; a book; a pyramid; and a treasure chest and wherein each of the sides and/or portions of the primary support structure comprises part of the item.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings illustrate a complete embodiment of the invention according to the best modes so far devised for the practical application of the principals thereof, and in which:

[0014] FIG. 1 depicts one embodiment of the primary support structure of the present invention.

[0015] FIG. 2 depicts one embodiment of the panels of the present invention.

[0016] FIG. 3 depicts a panel configuration of the present invention where the panel has a surface adapted for receiving a pliable material.

[0017] FIG. 4 depicts the steps in the assembly of a decorative structure from the kit of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] In general, the kit of the present invention comprises a three-dimensional primary support structure having at least one panel receiving slot and at least one panel having at least one panel tab extending therefrom. Each panel is of a shape corresponding to a portion of the primary support structure. Although the figures depict the structure as a house, it is understood that other structures such as: gingerbread houses; cruise ships; Noah's ark; Easter baskets; Christmas trees; plaques; signs; menus; birthday cakes; wedding cakes; cars; trucks, such as dump trucks; cities; gift boxes; castles; volcanoes; tee pees; draidels; wagons; window boxes; wishing wells; graduation caps; baby blocks; trains; churches; carousels; log cabins; animals; space ships; carry-out food boxes; cradles; books; pyramids; and treasure chests to name a few, are also included in this invention. As a most preferred embodiment, the structure is either a house, Easter basket, or a Christmas tree.

[0019] Referring now to the figures where similar elements are numbered the same throughout, FIG. 1 depicts one embodiment of the invention where the kit comprises a primary support structure 20 having a two-dimensional shape of a structure. The primary support structure 20 has at least one primary support structure tab 30 extending therefrom. The primary support structure 20 further comprises at least one primary support structure slot 40 and at least one panel receiving slot 50. It is understood to one of ordinary skill in the art that the primary support structure 20 may further include at least one flange (not shown) extending from at least one edge of the primary support structure. The flange is folded under the primary support structure or alongside the primary support structure to add further stability to and/or ease of assembly of the primary support structure. The flange may or may not be affixed to another part of the primary support structure. When affixing the flange to another part of the primary support structure, any means for attachment known to one of ordinary skill in the art such as: gluing, taping, stapling, or using some form of a fastener or adhesive may be employed.

[0020] Referring now to FIG. 2, the kit further comprises at least one panel 60. Each panel has at least one panel tab 70 extending therefrom. Each panel 60 is of a shape corresponding to a portion of the primary support structure 20 (of FIG. 1).

[0021] Referring back to FIG. 1, the primary support structure 20 is made of any material known to one of ordinary skill in the art. In cases where the primary support structure 20 is derived from a two-dimensional primary support structure, the material is such that it may be bent to form a three-dimensional structure and is strong enough to support the panels 60 (of FIG. 2) that are to be attached to the primary support structure 20. Preferably, the primary support structure 20 is comprised of a semi-rigid material that is folded to form a three-dimensional primary support structure (not shown). Most preferably, the semi-rigid material is a corrugated material such as corrugated cardboard or corrugated plastic board. Alternatively, other materials known to those of ordinary skill in the art may also be used for those cases where the primary support structure is pre-formed in three-dimensions. Examples of these materials include but are not limited to: perforated sheet metal, wood, wire mesh, wire grate material, aluminum, plastic, pliable corrugated plastic, baking stone, and baked clay.

[0022] FIG. 1 depicts a preferred embodiment of the invention where the primary support structure 20 is a single pre-cut piece in the shape of the structure (as shown, a house). However, it is understood in the art that the primary support structure 20 may have multiple pieces which are assembled together by inserting the primary support structure tab 30 into the appropriate primary support structure slot 40 to form the three-dimensional primary support structure 20. In the embodiment depicted in FIG. 1, the primary support structure 20 is a single piece which is folded along scored portions in the structure (depicted as heavy lines). The primary support structure tab 30 is then inserted into the appropriate primary support structure slot 40 to form the three-dimensional primary support structure 20. Alternatively, the three-dimensional primary support structure is pre-fabricated using conventional means so the end-user does not have to assemble the primary support structure.

[0023] In constructing a decorative structure using the kit of the present invention, panels 60 (FIG. 2) having shapes corresponding to various portions of the primary support structure are attached to the primary support structure (not shown) by the panel tabs 70 which extend from each panel. The panels 60 are made of any material known to one of ordinary skill in the art. For example, the panels are made of burlap; cardboard; plastic; canvas; metal; and wood. Preferably, the panels are made of cardboard; plastic; or metal. In one embodiment, the panels 60 are comprised of a material having at least one surface adapted for receiving a pliable material. FIG. 3 depicts one embodiment of the invention where one side 80 of the panel 60 is plain (or unmodified) and where the reverse side 90 of the same panel has been modified to receive a pliable material (not shown). The panel 60 surface is made adaptable by any means known to one of ordinary skill in the art. Such adaptations include but are not limited to perforation and corrugation. In one embodiment, several holes are made along the sides, top and bottom of the panel so the pliable material may be mechanically anchored into the panel. In another embodiment, the material used for the panels 60 is a corrugated material having at least one grooved surface. Most preferably, the panel 60 is made from a corrugated material having at least one grooved surface. The grooved surface of the panel is horizontal to the primary support structure after the panel tab is inserted into the panel receiving slot on the primary support structure.

[0024] As an alternative embodiment to the invention, the kit further comprises a pliable material. By pliable, it is meant that the material is flexible, capable of being shaped, or conforming to the shape of the surface on which it is placed. Any pliable material known to one of ordinary skill in the art is suitable for the present invention. In particular, such pliable materials include but are not limited to: a dough; a wax; a confection; a clay; and a plaster. Examples of a dough include but are not limited to: pastry dough; gingerbread; cookie dough (such as sugar cookie); and a cake dough. Waxes include all forms of wax such as beeswax and paraffin wax. Confections include candy mixtures such as gumdrops, chocolates, taffy, caramel, and hard candy mixtures. Clay includes modeling clay—both synthetic and natural. Plaster includes plaster of Paris, sheetrock, mud, and ceramic materials. In a preferred embodiment, the pliable material is a dough and most preferably, the dough is a gingerbread dough.

[0025] As yet another embodiment of the invention, the kit further comprises a storybook. The storybook tells a story about the structure and may or may not be fictional.

[0026] FIG. 4 depicts the steps in assembly for one embodiment of the invention where a decorative structure is assembled from a kit having a primary structure that is originally two-dimensional. The shape of the resulting decorative structure is dependent on the primary support structure provided in the kit. For example, if the primary support structure is a cruise ship, the resulting decorative structure will be a cruise ship. Although the figures depict the decorative structure as a house, it is understood that a house is only a preferred embodiment and that other decorative structures such as: gingerbread houses; cruise ships; Noah's ark; Easter baskets; Christmas trees; plaques; signs; menus; birthday cakes; wedding cakes; cars; trucks, such as dump trucks; cities; gift boxes; castles; volcanoes; tee pees; draidels; wagons; window boxes; wishing wells; graduation caps; baby blocks; trains; churches; carousels; log cabins; animals; space ships; carry-out food boxes; cradles; books; pyramids; and treasure chests are also included in this invention.

[0027] When practicing the method of the present invention, the kit is provided (FIG. 4, step 1). In the embodiment shown, the kit contains a primary support structure having a two-dimensional shape of a structure 20. The kit further contains a plurality of panels 60, each panel having a shape corresponding to a portion of the primary support structure 20. (Also see FIGS. 1 and 2.) The primary support structure 20 is folded and each primary support structure tab 30 is inserted into each corresponding primary support structure slot 40 (FIG. 4, step 2) to form a three-dimensional primary support structure 100 (FIG. 4, step 3). The primary support structure 20, is shown with flanges along the bottom 120 and sides 130 of the primary support structure 20 (FIG. 4, step 1). The flanges along the bottom 120 enable the structure to have additional support and not collapse. The flange along the side 130 further includes a means (such as an adhesive) for attaching the side flange 130 to a portion of the primary support structure 20 to form the three-dimensional structure. A pliable material is also provided. The pliable material is affixed to a side 90 of each panel 60. The pliable material is positioned on the panel such that it is integral with the panel and each panel tab 70 is left plain or partially uncovered by the pliable material 110 (step 4). The panels containing the pliable material 110 are attached to the primary support structure 100 by inserting each panel tab 70 into each panel receiving slot 50 on the primary support structure 100 (step 5). It is well understood that when the primary support structure is provided already in its three-dimensional form that the steps for assembling the primary support structure from a two-dimensional form into a three-dimensional form are not necessary or are omitted.

[0028] As a preferred embodiment, the pliable material is baked after it has been affixed to a side of each panel and before each panel is attached to the primary support structure. When the pliable material is to be baked, it may be desirable to modify the panel so that holes or perforations are made to the panel to allow moisture to escape from the pliable material as it is baked. The pliable material is affixed to the panel using any method known to one of ordinary skill in the art. In particular, the pliable material is affixed by the following method. The pliable material is first provided and then flattened onto a releasable surface. Any method of flattening the material is suitable for the present invention. In particular, the material is flattened by using a rolling pin. The releasable surface is preferably a surface of waxed paper or parchment paper. A panel is then placed onto the flattened pliable material. The panel is pressed into the pliable material. In the case where the surface of the panel is a grooved surface, it is desirable to provide enough pressure in the pressing process so that the material becomes integral with the panel. The pliable material is trimmed around the panel and the pliable material is removed from a portion of the panel tab. Lastly, the panel containing the flattened pliable material is removed from the releasable surface. As an additional step, the panel containing the flattened pliable material is removed from the releasable surface and is baked in an oven.

[0029] The decorative structures prepared using the kit of the present invention have some unique distinctions from those found in the prior art. In particular, all of the decorative structures have an underlying three-dimensional primary support structure to which panels containing a pliable material are attached. In other words, panels containing a pliable material are affixed directly to the primary support structure. The presence of the three-dimensional primary support structure overcomes the problem in the prior art where free-standing structures had a tendency to fall or crumble during assembly. Moreover, the panels of the instant invention become an integral part of the structure instead of being used as simply a means to form or cut out parts of the structure. The panels are actually embedded in the pliable material prior to attachment to the primary-support structure instead of removing the material from the panel as is done in the prior art. Once the panels having the pliable material are affixed to the primary support structure, the finishing touches such as covering seams and closing gaps with various cover materials, such as icing, are made. The kit of the present invention simplifies the art of making decorative structures and removes the problems associated with making such decorative structures.

[0030] The above description and drawings are only illustrative of preferred embodiments which achieve the objects, features and advantages of the present invention, and it is not intended that the present invention be limited thereto. Any modification of the present invention which comes within the spirit and scope of the following claims is considered part of the present invention.