WO1997003428A1

WO1997003428A1 - Greeting cards and other cards including novelty punch-out toys

Info

Publication number: WO1997003428A1
Application number: PCT/US1996/010907
Authority: WO
Inventors: David P. Burtch; Richard A. Burtch
Original assignee: Pop 'n Play, Inc.
Priority date: 1995-07-10
Filing date: 1996-07-09
Publication date: 1997-01-30
Also published as: GB9514057D0; AU6478996A

Abstract

A greeting card or other card is provided where the backplane (110) of the greeting card is made from a laminate of a relatively rigid expanded polystyrene material having a rebound characteristic. The laminate includes a paperboard layer which is capable of being printed upon. The backplane (110) of the greeting card may be printed with graphics and die-cut such that individual elements (112, 116) may be punched out of the card and assembled into a three-dimensional object such as a toy. For greater interest and value, the three-dimensional toy may be related to the message on the greeting card.

Description

GREETING CARDS AND OTHER CARDS INCLUDING NOVELTY PUNCH-OUT TOYS

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to greeting cards and other cards incorporating novelty toys including those adapted to be sold or given away in connection with promotions of various products and, more specifically, to greeting cards or other cards which include punch-out components that, when assembled, simulate an item of the type that children enjoy, such as a race car or a building.

2. Prior Art

As noted above, the present invention is concerned with, but is not limited to, novelty toys and devices which are sold as greeting cards or other types of cards or are useful as give-away items in connection with sales of a particular product or with product promotions in general. An obvious constraint on the commercial viability of such toys is that the toys must be very inexpensive to manufacture. On the other hand, in order for the toys to create interest, the toy must, generally, have a three- dimensional shape which approximates that of the item which it simulates. As well, while the three-dimensional shape, especially a detailed three-dimensional shape, helps to create interest, the toy must also be easy to assemble. Therefore, it is advantageous for there to be a minimal number of small punch- out elements to assemble.

Further, a variety of colors and graphics on the toy are useful in attracting and holding the attention of children. While various printing methods provide an inexpensive way to provide color and graphics on a toy, these printing methods do not lend themselves well to printing three-dimensional objects. One type of prior art greeting card is a "pop-up" card in which, with a certain movement (e.g., upon opening of the card), a projecting portion "pops up" out of the plane of the card to form a three dimensional card. While this pop-up design may increase the initial visual appeal of the card, such pop-up cards do not have punch-out elements that are assembled into a separate three-dimensional object or toy and, thus do not have the appeal of the invention as discussed below.

SUMMARY OF THE INVENTION

In accordance with the invention, a greeting card or other card is provided which is inexpensive to manufacture, and which includes or contains a punch-out toy or other item. The punch- out toy or item adds substantial appeal to the greeting card, particularly for children. For example, while an ordinary greeting card would normally be simply thrown away once read, the punch-out toy incorporated with the greeting card of the present invention can be used by a child over and over again.

The punch-out toy is easy to assemble into its component parts and, when assembled, simulates, in an appealing and interesting way, an item that children enjoy. The toy is constructed in a sturdy manner and is made of a sturdy polystyrene or polystyrene-like laminate material such that it can withstand relatively rough treatment from children during play. Further, the toy simulates not only the look of the item, but also the shape of the item, in a three-dimensional manner. Typically, the card is die-cut or scored in some other manner such that individual elements of the toy are retained within the card but are easily punched out of the card so that they may be assembled.

As mentioned above, a detailed three dimensional shape helps to create interest in the toy. While a detailed three- dimensional shape may be obtained by assembling a large number of punch-out elements, assembly of such a toy would be complex and difficult. The present invention eases assembly by providing for a type of pre-assembly comprising prior interconnection of various sub-elements of the toy into elements. Thus, some of the elements on the punch-out card comprise subelements that are interconnected. This interconnection is accomplished by scoring the element at the intersection of sub-elements, rather than cutting all the way through the card, so that, after being punched-out of the card, the uncut side of the card acts as a hinge and the sub-elements of the element may be folded in relation to each other, remaining firmly attached to said element. Therefore, when these elements are punched out of the card, the sub-elements do not necessarily require additional connection to the elements. Therefore, much less assembly is needed in order to produce a relatively intricate three- dimensional toy. Furthermore, the polystyrene laminate material has a certain resilient flexibility. Thus, if an opening is formed in the material and a slightly oversize element is forced into the opening, the element is then gripped by the material.

Further, because in accordance with the present invention, the toy or item is made, essentially, from one punch-out card, the card can easily and inexpensively be printed with colorful graphics, and the like, before the elements are punched out. Thus, the assembled toy is an inexpensive three-dimensional toy with the added appeal of such graphics.

In a preferred embodiment, wherein the punch-out card is included as part of a greeting card, the greeting card preferrably carries both a thoughtful message, such as provided by conventional greeting cards, as well as an interesting toy and, advantageously, the toy is specifically related to the message. For example, the greeting card contain a message wishing a boy a happy 5th birthday and the toy may be a racing car bearing the number 5 or the greeting card may contain the likeness of a racing car driver and the toy may be a racing car bearing the likeness of the driver's car or the greeting card may be a thank you to customers of a particular business and the toy may be a replica of that business building. In another embodiment, the greeting card may congratulate a new owner of a house and the toy or item may be a three-dimensional house.

Generally, all the component parts of the toy are punched out of a single punch-out card. However, the toys of some preferred embodiments require an additional, commonly found article, such as a plastic straw, to complete the assembly.

In one embodiment of the present invention, the novelty punch-out toy card of the invention comprises punch-out elements (and associated sub-elements) which, when assembled with the additional element of a plastic straw, simulate, in a three- dimensional manner, a race car. In this embodiment, a chassis element preferably comprises subelements which form the various portions of the chassis, while front and rear body elements comprise subelements which form the body portions of the race car. Similarly, other elements simulate various other features of a race car. Additionally, front and rear wheel assemblies are advantageously formed by using portions of a plastic stirring straw as axles and wide stable wheels are simulated by stacking or layering together a plurality of punch-out wheel elements to form each wheel. The wheel assemblies are attached to the chassis of the race car in such a way that they are free to rotate.

A further aspect of the invention involves the provision of a kit for producing a model comprising a sheet or card of material having a layer of polystyrene material with paper or paperboard bonded to at least a first face; a plurality of components delimited by cut lines or lines of weakness so that they are separable from the rest of the sheet; and at least one component having at least one fold line formed by a cut extending substantially through the material but not severing the paper at the first face. Preferably, one or more components are adapted to be arranged to define a box structure, i.e., a structure defining a volume. Preferably, at least one component has an opening for receiving an oversized element which is thereby gripped. For example, a slot may receive one or more thicknesses of the sheet material which is thus gripped to stabilize a structure. A wheel may comprise at least one disk of the polystyrene laminate sheet material having a small central hole into which an axle rod (e.g., constructed by a wooden or plastic rod or a plastic tube such as a portion of a drinking straw) is forced.

Other features and advantages of the present invention will be set forth in, or will become apparent from, the detailed description of the preferred embodiments of the invention which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a greeting card in accordance with a preferred embodiment of the invention.

Figure 2 is a plan view of one embodiment of the backplane punch-out card of the greeting card shown in Figure 1.

Figure 3 is an exploded view of the wheel assemblies shown in Figure 2.

Figure 4 shows a fully assembled punch-out toy race car of the type shown in Figure 2.

Figure 5 shows an exploded view of the assembled toy race car of Figure 4.

Figure 6 shows a plan view of a second embodiment of a punch-out toy card of the type shown as the backplane card of the greeting card shown in Figure 1.

Figure 7 is an exploded perspective view showing assembly of the punch-out toy card of Figure 6.

Figure 8 shows a perspective view of the assembled toy of Figures 6 and 7.

DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference now to the drawings in which like numerals represent like elements throughout the several views, Figure 1 shows a greeting card in accordance with the present invention. Front cover 108 is hingedly attached along one edge to backplane punch-out card 110. Card 110 is relatively rigid with respect to a normal greeting card and, in accordance with an important feature of the invention,is preferably made out of a laminate of expanded polystyrene with paper or paperboard laminated to the front and back surfaces thereof. The paper or paperboard is of a type that is readily printable by any number of conventional printing methods. A plastic film or coating on the paper or paperboard is preferably provided for protective purposes. Front cover 108 and card 110 may be made of the same material, in which case a simple fold may hingedly attach front cover 108 to card 110, or front cover 108 may be made of a different material from that of card 110 in which case front cover 108 may be attached to card 110 by gluing a folded over portion of front cover 108 to card 110, as indicated at 109.

The relatively rigid expanded polystyrene material of card 110 can easily be die-cut and has enough "rebound" or tendency to return to a pre-co pressed state to allow any die-cut elements to securely remain within card 110 until they are punched out by the user. Further, the "rebound" characteristic of the material provides for secure attachment of elements to eachother by simply compressing a portion of one element, for example, a tab, when inserting it into a portion of another element, for example, a slot. The rebound of the polystyrene material forming such a tab will provide secure attachment to the material forming such a slot.

Referring to Figures 2 through 5, there is shown a novelty punch-out toy in accordance with an embodiment of the invention. The card, which is generally denoted 110 in Figure 2, is the same card which forms the backplane of the greeting card shown in Figure 1 and includes punch out components or elements which, when assembled, simulate a race car. Card 110 is die-cut to form the elements and the sub-elements such that the elements and sub¬ elements remain part of the card until they are punched-out in preparation of assembly.

The punch-out elements of the toy car include a chassis element 112 including subelements 112a, 112b, 112c, H2d, I12e, 112f, 112g, and 112h as well as a slots ll2i, 112j, and 112k; a front body element 114 including subelements 114a, 114b,and 114c; a rear body element 116 including subelements 116a, 116b, 116c, and slots 116d, 116e, and 116f; a rear axle cover element 118; a front axle cover element 120; a seat element 122, including subelements 122a, 122b, 122c, and 122d and slots 122e and 122f; spoiler element 124, including slot 124a; spoiler cap elements 126 and 128; six front wheels, each labeled 130; and eight wheels, each labeled 132.

Figure 3 shows the wheel assemblies for the punch-out toy race car of Figure 2. A straw, typically a small diameter stirring straw, is used to form front axle 102 and rear axle 104. The straw is cut in half and each half forms an axle. Rear wheel assembly 108 is formed by inserting each end of rear axle 104 through the center holes of four rear wheels 132. Front wheel assembly 106 is formed by inserting each end of front axle 102 through the center holes of three front wheels 130. Thus, the composite wheels have the appearance and functional effect of being wider than would ordinarily have been possible by just using a single punch-out wheel on each end of each axle. Further, these wide wheels have more stability than would be possible with thin wheels made out of only one layer of material.

Referring now to Figures 4 and 5, there is shown in Figure 4 a fully assembled punch-out toy race car of the type shown in Figure 2, and there is shown in Figure 5 an exploded view of the assembly of Figure 4. After all the elements are punched out of card 110, the various elements are formed by folding the related subelements as shown in Figure 5. Chassis element 112 is formed by folding subelements 112a and ll2g at right angles to subelements 112b and 112f, respectively, and inserting subelements 112a and 112g into slot 112j. Subelements 112h and 112i are folded vertically to the plane of the chassis element to form a support for the spoiler 124. Seat element 122 is formed as shown and inserted onto chassis element 112 such that slots 122e and 122f engage the cut-out portions of subelements 112b and 112f. Wheel assemblies 106 and 108 are placed onto chassis subelement 112d at the positions indicated.

Rear body element 116 is formed by folding subelements 116a, 116b and 116c at right angles to eachother, as shown, and front body element 114 is formed by folding subelements 114a, 114b and 114c at right angles to eachother, as shown. Rear axle cover element 118 is inserted into rear body element 116 through slots H6f (hidden) and llβe. Front axle cover element 120 is inserted into front body element 114 through slots 114d (hidden) and 114e. Next, rear body element 116 is positioned onto chassis element 112. Tab 116i is inserted into slot 112k and tab 116j is inserted into slot 1121. Rounded slots 116g and 116h (hidden) are located such that they trap axle 104 of rear wheel assembly 108 against chassis subelement H2d, however axle 104, and therefore, wheel assembly 108, may rotate freely. The tip of seat subelement 122d is inserted into slot 116d of the rear body element.

Front body element 114 is then positioned onto chassis element 112. Tab 114j is inserted into slot 112k, just in front of tab 116i and tab 114k is inserted into slot 1121, just in front of tab 116 . Slots 114g and 114h (hidden) are positioned onto chassis subelement 112d such that they trap axle 102 of front wheel assembly 106, as shown, however, axle 102, and therefore, wheel assembly 106, may rotate freely.

Spoiler 124 is positioned such that the tips of chassis subelements ll2h and 112i project through slot 124a. Spoiler ends 126 and 128 are positioned over spoiler tabs 124b and 124c, respectively.

Instructions for assembly of the elements may be provided on a portion of either the front or back of card 110 or on a portion either the front or back of front cover 108 or they may be provided on a separate sheet.

A second embodiment of a punch-out card is shown in Figures 6 through 8. Figure 6 shows a planar view of punch-out card 210 which can be attached to front cover 108 shown in Figure 1 in similar manner to backplane punch-out card lio. The elements of card 210 are formed by die-cutting and may be punched out and assembled to form a three dimensional toy building.

Building element 212 is shown with its associated subelements: subelements 212a and 212b, having edge slots 212n and 212o and 212p and 212q, respectively; subelement 212c having slot 212e; subelement 212d, having tabs 212j, 212k, 2121, and 212m; and subelement 212r having window cutouts 212s and 212t, tabs 212f and 212g, and slots 212h and 212i. Inner window element 214 includes slots 214a and 214b. Chimney element 216 includes subelement 216a having hole 216c and subelement 216b having hole 216d. Sign element 218 includes tabs 218a and 218b.

Figure 7 is a perspective view showing assembly of the punch-out toy building and Figure 8 shows a perspective view of the building of Figures 6 and 7 in the assembled condition. Referring to Figure 7, tabs 212f and 212g are folded at right angles with subelement 212r and inner window element 214 is positioned adjacent to subelement 2l2r such that tabs 2l2f and 212g are inserted through slots 214b and 214a, respectively. Chimney element 216 is formed by folding subelement 216a over onto subelement 212b. Chimney element 216 is then inserted through slot 212e, as shown. Subelements 212a and 212b are folded at right angles with subelement 2l2r and subelement 2l2d is folded over subelements 212a and 212b and tabs 212j, 212k, 2121, and 212m are inserted into edge slots 212q, 212p, 2l2o, and 212n, respectively. Tabs 218a and 218b of sign element 218 are inserted into slots 212h and 212i respectively.

It can be seen in Figure 8 that the layering of inner window element 214 behind window cutouts 212s and 2l2t gives a three dimensional appearance to the windows. Also, the layering of sign element 218 over building subelement 212r gives a three dimensional appearance to the sign.

A string or hook, such as a Christmas tree ornament hook, may be inserted through holes 216c and 216d to suspend the building in ornament fashion. Further, if made from an appropriate fragrant material, a three-dimensional item in accordance with the present invention, such as the building of Figures 6 through 8 may also be used as an air freshener, such as those that are hung from the rear view mirror of an automobile.

Although the invention has been described in detail with respect to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the spirit and scope of the invention.

Claims

I claim:

1. A greeting card comprising: a front cover having at least one edge; and a back card member made from a laminated polystyrene material and having at least one edge, said at least one edge of said front cover being hingedly attached to said at least one edge of said back card member such as to enable said front cover to be positioned both in a coplanar orientation with respect to said back card member and in a non-coplanar orientation with respect to said back card member.

2. A greeting card as in claim 1, wherein said back card member comprises a plurality of elements which can be readily punched out of said back card member and which are capable of being assembled to form a three-dimensional object.

3. A greeting card as in claim 2, wherein said elements are die- cut from said back card member and remain contained within said back card member until punched out therefrom.

4. A greeting card as in claim 3, wherein at least one of said elements contains subelements which are hingedly attached to said one of said elements.

5. A greeting card as in claim 1, wherein said expanded polystyrene or polyethylene material is laminated with a paperboard layer which is capable of being printed upon.

6. A greeting card as in claim 2, wherein said greeting card has an inscription and said three-dimensional object is related to said inscription.

7. A greeting card as in claim 2, wherein said three-dimensional object is a toy vehicle having at least one axle and wherein said axle comprises a portion of a plastic drinking straw.

8. A greeting card as in claim 7, wherein said plurality of elements include a plurality of substantially equal size disk shaped elements for, when punched out and assembled, forming wheels of said toy vehicle.

9. A greeting card as in claim 2, wherein said plurality of elements are shaped such that said three-dimensional object is a building.

10. A greeting card as in claim 2, wherein means is provided for hanging said three dimensional object, when punched out and assembled.

11. A greeting card as in claim 2, wherein the material of said card member includes a fragrance and said three-dimensional object comprises an air freshener.

12. A greeting card as in claim 1, wherein said front cover is made from a different material than said back card member.

13. A greeting card as in claim 1, wherein said front cover and said back card member are made from the same material.

14. A punch-out card comprising: a card member made from a laminated polystyrene material and comprising a plurality of elements which can be readily punched out of said card, said plurality of elements, when punched out, being capable of being assembled to form a three-dimensional toy vehicle, said elements including first and second elements which respectively comprise a top portion and a bottom portion of the vehicle and which, when assembled, are attached together to define a volume comprising a vehicle body, said elements further including a plurality of disk shaped elements which, when assembled, are stacked in side by side relation to form wheels which have a thickness of the combined thickness of the stacked disk shaped elements.

15. A punch-out card as in claim 14, wherein each of said plurality of elements is die-cut from said card and remains a part of said card until punched out therefrom.

16. A punch-out card as in claim 14, wherein said expanded polystyrene or polyethylene material is laminated with a plastic film which is capable of being printed upon.

17. A three-dimensional toy vehicle comprising a plurality of elements made from a laminated polystyrene material having a rebound characteristic that provides secure attachment of at least one of said elements forming a top portion of said vehicle to at least a further one of said elements forming a bottom portion of said vehicle, said top portion and said bottom portion being attached together to define a volume comprising a vehicle body.

18. A three-dimensional toy vehicle as in claim 17, further comprising wheels mounted on said vehicle body and formed by a plurality of disk shaped elements stacked in side by side relation so that said wheels have thickness equal to the combined thickness of the stacked disk shaped elements.

19. A three-dimensional toy vehicle as in claim 18, further including at least one axle connected to said wheels, said axle comprising a portion of a plastic straw.