Foldable playard having x-frame assemblies and canopy cover
A foldable playard includes a frame defining an interior space when unfolded and soft goods partially disposed within the interior space to define a partially enclosed space for a child to play and/or sleep. The frame includes multiple leg support assemblies and multiple X-frame assemblies that couple adjacent leg support assemblies together. The X-frame assembly is positioned near the top of the frame when the playard is unfolded such that the X-frame assembly functions as a top rail to mechanically reinforce the playard. In this manner, the playard does not include a separate compliant or rigid top rail or a bottom support structure, thus reducing the number of parts for manufacture. Additionally, the playard includes a single latch mechanism to maintain the playard in the unfolded configuration. The playard may also include an optional canopy cover assembly mounted to the frame to provide shade for the child.
1. A frame for a foldable playard, the frame having a compact folded configuration for storage of the frame and a deployed unfolded configuration to support the foldable playard, in an upright position on a ground surface, to contain a child in an interior space of the foldable playard, the frame comprising:
a plurality of leg support assemblies extending upward from the ground surface when the frame is in the deployed unfolded configuration, each leg support assembly of the plurality of leg support assemblies comprising:
a bottom end supported by the ground surface; and
a top portion opposite to the bottom end; and
a plurality of X-frame assemblies coupled to the plurality of leg support assemblies, each X-frame assembly of the plurality of X-frame assemblies being coupled to respective top portions of adjacent leg support assemblies of the plurality of leg support assemblies when the frame is in the deployed unfolded configuration such that, in the deployed unfolded configuration of the frame:
the plurality of X-frame assemblies forms a top perimeter structure of the frame outlining the interior space of the foldable playard,
wherein the plurality of X-frame assemblies constitutes the only interconnection in the frame between respective pairs of leg support assemblies of the plurality of leg support assemblies.
2. The frame of claim 1 , wherein a shape of the top perimeter structure is one of a square, a rectangle, or a hexagon.
3. The frame of claim 1 , wherein a first X-frame assembly of the plurality of X-frame assemblies is coupled to a first top portion of a first leg support assembly of the plurality of leg support assemblies, and wherein the frame further comprises:
one latch mechanism coupled to the first X-frame assembly to constrain movement of the first X-frame assembly and thereby maintain the frame in the deployed unfolded configuration, the one latch mechanism being disposed proximate to the first top portion of the first leg support assembly.
4. The frame of claim 3 , wherein the frame comprises only the one latch mechanism to maintain the frame in the deployed unfolded configuration.
5. The frame of claim 1 , wherein each leg support assembly of the plurality of leg support assemblies comprises:
a leg tube having a top end;
a corner coupled to the top end of the leg tube; and
a slider slidably coupled to the leg tube such that the slider is disposed proximate to the corner in the top portion of the leg support assembly when the foldable playard is in the unfolded configuration.
6. The frame of claim 5 , wherein the leg tube of each leg support assembly has an oval-shaped cross-section.
7. The frame of claim 5 , wherein:
respective sliders in the plurality of leg support assemblies are identical; and
respective corners in the plurality of leg support assemblies are identical.
8. The frame of claim 5 , wherein:
the plurality of leg support assemblies comprises:
a first leg support assembly comprising a first corner and a first slider; and
a second leg support assembly comprising a second corner and a second slider; and
the plurality of X-frame assemblies comprises a first X-frame assembly disposed between and coupled to the first leg support assembly and the second leg support assembly, the first X-frame assembly comprising:
a first X-tube rotatably coupled to the first corner of the first leg support assembly and the second slider of the second leg support assembly; and
a second X-tube rotatably coupled to the second corner of the second leg support assembly and the first slider of the first leg support assembly, the second X-tube being rotatably coupled to the first X-tube.
9. The frame of claim 8 , wherein:
respective leg tubes of the first leg support assembly and the second leg support assembly have identical lengths (L);
the first X-tube and the second X-tube of the first X-frame assembly are positioned within respective top portions of the first leg support assembly and the second leg support assembly when the frame is in the deployed unfolded configuration; and
the respective top portions of the first leg support assembly and the second leg support assembly constitute less than or equal to 20% of the identical lengths.
10. The frame of claim 9 , wherein:
the first X-frame assembly is coupled to a first top portion of the first leg support assembly;
the frame further comprises one latch mechanism coupled to the first X-frame assembly to constrain movement of the first X-frame assembly and thereby maintain the frame in the deployed unfolded configuration, the one latch mechanism being disposed proximate to the first top portion of the first leg support assembly; and
the frame comprises only the one latch mechanism to maintain the frame in the deployed unfolded configuration.
11. The frame of claim 10 , wherein:
the first X-tube and the second X-tube of the first X-frame assembly are coupled to each other via a rivet joint; and
the rivet joint comprises a rivet inserted through a hole formed in the first X-tube and the second X-tube, the hole being dimensioned to be larger than the rivet so as to ensure the bottom end of each leg support assembly of the plurality of leg support assemblies contacts the ground surface when the frame is in the deployed unfolded configuration.
12. The frame of claim 10 , wherein the one latch mechanism directly couples together the first corner of the first leg support assembly and the second X-tube of the first X-frame assembly when the latch mechanism is in a locked configuration.
13. The frame of claim 12 , wherein the one latch mechanism comprises:
a latch boss directly coupled to the second X-tube of the first X-frame assembly and disposed proximate to the first slider of the first leg support assembly, the latch boss having an undercut portion; and
a latch member coupled to the first corner of the first leg support assembly, the latch member having a latch opening and a tab disposed within the latch opening,
wherein the undercut portion of the latch boss rests on the tab of the latch member when the one latch mechanism is engaged thereby maintaining the frame in the deployed unfolded configuration.
14. The frame of claim 13 , wherein:
the latch boss further comprises a central rib partially disposed within the undercut portion; and
the latch member further comprises a central slot disposed within the tab so as to align the latch member to the latch boss when the one latch mechanism is being engaged.
15. The frame of claim 14 , wherein:
the one latch mechanism is configured to be engaged by moving the first slider of the first leg support assembly towards the first corner of the first leg support assembly until the latch member snaps onto the latch boss such that the tab of the latch member contacts the undercut portion of the latch boss; and
the one latch mechanism is configured to be disengaged by squeezing the first and second X-tubes together to release the tab of the latch member from the undercut portion of the latch boss and, while squeezing the first and second X-tubes together, pulling the latch member away from the latch boss.
16. The frame of claim 10 , in combination with soft goods to form the foldable playard and define the interior space of the foldable playard when the frame is in the deployed unfolded configuration, wherein the soft goods are coupled to the plurality of leg support assemblies so as to cover respective corners of the plurality of leg support assemblies and at least a portion of the plurality of X-frame assemblies.
17. The frame of claim 16 , wherein:
the soft goods comprises one or more snap-fit connectors that couple to corresponding snap-fit receivers disposed on the corner of each leg support assembly of the plurality of leg support assemblies.
18. The frame of claim 17 , wherein the soft goods cover all of the plurality of X-frame assemblies when the frame is in the deployed unfolded configuration.
19. The frame of claim 18 , wherein the soft goods comprises a floor portion that directly contacts the ground surface when the frame is in the deployed unfolded configuration.
20. The frame of claim 19 , wherein:
the soft goods comprises a see-through portion disposed along one or more sides of the interior space when the frame is in the deployed unfolded configuration; and
the plurality of X-frame assemblies are positioned in respective top portions of the plurality of leg support assemblies so as not to block the see-through portion of the soft goods when the frame is in the deployed unfolded configuration and thereby not significantly impede the visibility of the child when the child is in the interior space of the foldable playard.