CORNHOLE GAME BOARD

Description

BACKGROUND OF THE INVENTION

The present invention relates to cornhole game boards, and more particularly to lightweight, thin, strong and weather resistant game boards made from upper and lower opposing pan-like galvanized steel skins forming an empty hollow box. A cornhole bag hole is centered and cut through the upper portion of the hollow box. A thin slice of PVC pipe, or an injection molded plastic spacer, is bonded between the skins at the hole to seal the hole opening. Expanding polyurethane foam is injected into the hollow box where it is cured and forms a hard, strong, rigid board encapsulated in steel. Folding legs support the board as the game is played on the ground or floor.

A cornhole bean, beads or corn bag toss game is defined as two team players taking turns throwing fabric corn bags at an inclined board with a hole near its rear end. The goal of the game is to score points by either landing a 6-inch by 6-inch corn-filled bag on the board (one point) or putting a bag through the hole (three points). The game was first described in a patent in 1883. The inclined boards are generally 24 inches wide and 48 inches ( or 36 inches) long with a 6-inch hole centered and 9 inches from the back of the boards. The boards are placed about 33 feet (center of hole to center of hole) or 27 feet (front edge to front edge of the board) apart.

Cornhole boards are almost always made of wood which can be quite ornate. The top board with the hole is usually solid and about ½ inches thick and is attached to dimensional 2x4-inch lumber with a nice, smooth-gliding finish to assist the bags in sliding on the boards. The boards have fold-out legs. Typical wood-constructed game board sets are generally each 4 inches in edge depth or more. At 4 inches of depth, two game boards with packaging materials are likely to be no less than 8 to 9 inches in depth or more. Such nice, ornate wooden boards are heavy, nicely finished, and generally cost over $100 USD and up to $300 USD or more. Problems with wooden boards are that they are subject to wear and tear and are not weatherproof.

SUMMARY OF THE INVENTION

The present application relates to a lightweight cornhole game board that has aligned and upper and lower opposing metal skins with all four edges of the upper skin folded approximately 90º downwardly, forming a downward-facing pan. All four edges of the lower skin are folded approximately 90º upwardly, forming an upward-facing pan. The upper skin four edges slip tightly over the four edges of the lower pan and are sealed together, forming generally a 24-inch by 48-inch hollow metal box. A 6-inch round hole passes through an upper portion of the hollow metal box whereat a slice of a PVC pipe or an injection molded plastic spacer is bonded within the hollow metal box surrounding the hole. A closed-cell, two-part polyurethane-like foam is injected, expanded and cured into a rigid, strong material within the hollow metal box through a closeable foam port as the box is held in press to keep all sides and edges flat further and holds the PVC pipe in place. Pivoting long legs and short legs are fastened to the edges or bottom side of the metal box. A pivoting carrying handle is fastened midway to a side edge of the hollow metal box.

A principle object and advantage of the present cornhole board invention is that the board may be played as a bare galvanized steel surface, painted with spray cans, decorated vinyl, magnetic overwraps, or custom graphics.

Another principle object and advantage of the present invention is that the board uses Ecofoam® materials which are made with natural plant based ingredients like cornstarch and soy oil. Ecofoam® is a U.S. Federally Registered Trademark owned by Foam Supplies, Inc. of St. Louis, Missouri. Typical wood constructed game board sets are generally 4 inches in edge depth or more. At 4 inches of depth, two game boards with packaging materials are likely to be no less than 8 to 9 inches in depth or more. The manufacture of the present invention boards requires 68% less energy requirements and 76% less greenhouse gas emissions than other comparable amounts of polyethylene foam. Ecofoam® is 100% environmentally friendly, water soluble and is a compostable solution to traditional packaging foam. That is, has no Ozone depleting chemistry, does not generate any ozone depleting gases, is Volatile Organic Compound (VOC) free. Ecofoam® is formulated to develop a closed-cell structure that adheres to the steel skins, creates a rigid board/lamination, is encapsulated in the steel, and won’t absorb water or break down. The use of injected polyurethane foam is also the most effective and efficient method of developing lamination. Alternatively to the injected format, the use of sheet foam board stock cut to size and adhered with adhesive within the hollow box would yield much greater scrap and waste material while adding more chemicals to the process that are otherwise not necessary.

Another principle object and advantage of the present invention is that the board set weighs just over 20 lbs. with legs and carry handle. This is a desirable feature when carrying the game board, transporting, and storing the game boards.

Another principle object and advantage of the present invention is that the edge of the metal or steel that meets the bag hole or opening in the board is machined with a Titanium bit to round-over the upper and lower edge opening to create a burr-free safe passage of bags and unprotected hands. This rounding over also contributes to smooth play and unrestricted bag slide and movement on the board surface and passage through the hole.

Another principle object and advantage of the present invention is that the legs feature stiffening ribs. Both legs also are mounted to the side of the board by a screw, pivot pin, rivet, or rivnut that secures the leg to the board edge at a precise location pre-punched to align the screw, drill bit, or rivet. There is a reinforced edge (hem) on the board at these locations to increase the material for a more substantial attachment point. By this arrangement, both legs snugly fold up flat to the game board for transport and storage.

Another principle object and advantage of the present invention is that both legs are precision engineered to fold flat onto the underside of the board for ease of storage, transport, and carrying.

Another principle object and advantage of the present invention is that the tall leg (back leg near the hole in the board) features a cut-out or aperture in the leg to facilitate the hanging of the board on a hook, bracket, or heavy-duty screw that must be attached in a way to support each board at 20 lbs. or both at 40lbs. The cutout also allows for the player to easily set up the game by opening the legs for play.

Another principle object and advantage of the present invention is that each leg features the use of a metal reinforced rubber edge protector on all surfaces that are not folded over. The folded steel is called a hem, and it provides protection from sharp edges and greatly improves the strength of the part. The hemmed sides of the game board legs are then folded or bent 90 degrees at a precise inside dimension to fit tightly over the sides of the game board for attachment.

Another principle object and advantage of the present invention is that there is a specific height of the leg attachment on the game board so the legs will rest “over-center” locking into position. In addition, this precise leg and attachment hole dimension properly establishes the game board playing height to meet the regulations of 4 inches front board height and 12 inches back board height.

Another principle object and advantage of the present cornhole board invention is that each leg also features a recessed center section that creates two distinct foot pads for the game board to rest on (four total). These foot pads are covered with the steel reinforced rubber edge cover to enhance the grip on smooth surfaces and provide a larger surface area for the game board to rest on.

Another principle object and advantage of the present invention is that an optional heavy duty legs is being offered that allows for the locking of the legs into position for heavy/rough service, rambunctious play, or environments where it is possible that players may step on the playing surface out of frustration. The game board will fail before they collapse from being over loaded. Applicant has conducted simple tests that featured three grown men standing on the game board surface. With the use of the heavy-duty legs and the board and legs fully supported the weight of 725lbs. The heavy-duty legs are welded steel tubes attached to a locking pin hinged base that is attached to the four underside corners of the game board with screws or rivets. The heavy-duty legs do not fold flat onto the surface of the game board, they project off the surface 1.25 inches. The heavy-duty legs are painted black.

Another principle object and advantage of the present invention is that the game board carry handle is like one that would be utilized on a briefcase, or case utilized for the transport of valuable equipment. Each game board features pre-punched holes for the attachment of the carry handle by the end-user. Four special screws for attachment of the handle to the edge of the game board. When the handles are installed, it is possible to carry both game boards in one hand, however 40 lbs. may be more than most will be comfortable with. In this configuration the handles allow for the wrapped (playing surface) of the boards to be facing each other for protection. If carried one per hand, the playing surface can be towards the person carrying the boards and won’t catch on their legs or the board game legs. This arrangement is much unlike typical wood constructed game board sets are generally 4 inches in edge depth or more. At 4 inches of depth, two game boards with packaging materials are likely to be no less than 8 to 9 inches in depth or more. This makes handling, shipping, storing and transportation more of a challenge. Weights can also vary depending on the material used and this can also add to the challenge of using, storing, and transporting the wood construction board sets.

Another principle object and advantage of the present invention is that the game board surface requires no processing, sanding, or filling to create a perfectly smooth surface. The board can be played as a bare galvanized surface, painted with spray cans, and can be easily masked off to create patterns.

Another principle object and advantage of the present invention is that the playing surface is also ideal for the use of vinyl wraps that have graphics printed on them. The graphics are readily available from a variety of sources, and it is possible to have custom graphics and images created. Application of these vinyl wraps can be performed by the board owner with basic instruction and the use of a squeegee designed for the task. It is a mid-skill level process. Professional results are assured if the graphic is applied by a skilled and practiced individual.

Another principle object and advantage of the present invention is that unique from wood, typical game board material is the fact that the steel is a fantastic surface to apply magnetic or vinyl graphics to the game board. This flexibility allows for themed game board graphics to be applied and removed easily and at relatively low cost. Graphics can be applied that recognize a specific event, corporate image, personalized moment, fundraising opportunity, or just change the board surface to change the game from traditional cornhole to a sports theme or playing card graphic. This is not easily accomplished with a wood construction board. It requires special finishes and is not nearly as receptive as the metal to holding the graphic.

Another principle object and advantage of the present invention is that it requires no maintenance, unlike wood boards which are subject to damage from chipping, swelling, warping, and may require the tightening of fasteners such as screws and bolts as the wood swells and shrinks due to changes in humidity. None of these are factors with the present game board materials and design.

Another principle object and advantage of the present invention is that its ability to create the best possible finished steel attributes is due to the ability of the steel mills to create cocktails of metal attributes that can provide durability, flexibility, forming and machining ease, and smoothness that is outside the capability of wood and all with high levels of recycled content.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the cornhole board set on the ground, legs folded outwardly and ready to play on the ground or floor;

FIG. 2 is a side elevation view of the opposing upper skin pan and lower skin pan ready to be joined;

FIG. 3 shows a partially broken away, cross sectional view of the end walls, edges or lips of the pans ready to be joined together with the foam seal cap open;

FIG. 4 is a side elevational view of the joined pans in a heated press exerting great force as the foam is injected into the hollow space of the hollow metal box, the foam core creates a flat, rigid, light weight, strong and rigid game board;

FIG. 5 shows a partially broken away, cross sectional elevation view of the opposing upper skin pan and lower skin pan joined together with the foam spray nozzle inserted and spraying foam into the hollow metal box;

FIG. 6 shows a partially broken away, cross sectional elevation view of the opposing upper skin pan and lower skin pan joined together with the foam expanding within the hollow metal box within the press;

FIG. 7 is a cross sectional view partially broken away taken along lines 7-7 of FIG. 1;

FIG. 8 is a rear perspective view of the cornhole board set on the ground, legs folded outwardly and ready to play on the ground or the floor;

FIG. 9 is a side elevational view of the cornhole board with handle and legs folded outwardly from storage positions (in phantom);

FIG. 10 is a rear perspective bottom view of the cornhole board on the ground with the legs folded inwardly ready for transportation and/or storage;

FIG. 11 is a front perspective view of the cornhole board set on the ground with a replaceable magnetic or vinyl wrap with graphics ready to be lower onto the board and squeegeed into place; typical magnetic wrap covers the entire playing surface. Cutting the hole is accomplished with the use of a razor blade or utility knife.

FIG. 12 is a front perspective view of the cornhole board set on the ground with a replaceable magnetic or vinyl wrap ready to be lower onto the board and squeegeed into place, the guides, separate magnetic strips placed as desired by the players, assist novices or children in learning how to throw the corn or bean bags into the hole; Magnetic wrap typically covers the entire playing surface

FIG. 13 is a front perspective view of the cornhole board set on the ground with a replaceable magnetic or vinyl wrap and raised guides mounted onto the board, the guides assist novices or children in learning how to throw the corn or bean bags into the hole; show wrap full size of board

FIG. 14 is a perspective view of the one of the heavy duty legs comprised of welded steel tubes attached to a locking pin hinged base that is attached to one of the four underside corners with screws or rivets;

FIG. 15 is a side elevational view, the board partially broken away, of the rear and front heavy duty legs attached to one of the four underside corners with screws or rivets showing extended and storage positions (in phantom); and

FIG. 16 is a front perspective view of the cornhole board set on the ground, heavy duty legs folded outwardly and ready to play on the ground or floor.

DETAILED SPECIFICATION

Referring to FIGS. 1, 2, 8, 9 and 10, the construction of the cornhole game board 10 may be appreciated. The upper galvanized steel skin or play surface 12 has depending 90º side walls, lips or side edges 14 formed by a folding machine or brakepress. Thus an upper pan 16 is formed with a foam port 18. The lower skin 20 has uprising 90º side walls, lips or side edges 22. Thus a lower pan 24 is formed with a foam port 26 with an inside the box suspended cap 28 that is biased closed. The pans 16 and 24 are suitably of 24-gauge steel that is galvanized (zinc-dipped) to guard against rust. This arrangement forms a hollow metal box 29.

A 6-inch bag scoring hole 32 is center located 89 inches from the top of the game board 10. A one-inch slice of 6-inch PVC pipe or injection molded plastic sleeve 34 is bonded in place at the hole sealing the hollow metal box 29 from the outside. The hole or opening 32 in the board is machined with a titanium bit to round-over the upper and lower edge opening to create a burr-free safe passage 35 of bags and unprotected hands. This rounding-over also contributes to smooth play and unrestricted bag slide and movement on the board surface and passage through the hole. A side edge 14 carrying handle 36 maybe be firmly fastened thereat with screws, rivets or the like.

Rear legs 40 hold the rear of the board 10 12 inches off the ground or playing surface and are rotatably held in place by a pivot pin 41 or the like. The legs 40 are suitably made with 20-gauge sheet metal. Rear legs 40 have reinforcing ribs 42. A lower recessed center section 44 forms two foot pads 46. Side edge folded hems 48 further add reinforcement to the rear legs 40. An oval cut opening, aperture or hole 50 aligns with the 6 inch bag hole 32. This option allows for safe handling and hanging the board 10 on a hook or screw on a wall out of the way. When the legs 40 are folded up, they are flush with the bottom pan 24. The legs 40 are held in folded condition by friction between hems 48 and upper side edges 14. When the legs 40 are extended, they are folded out, they will rest over-center of the of the pivot pin 41 as top edge 52 abuts against the bottom pan 24. All non-hemmed edges and oval cut out 50 have a steel reinforce rubber edging or trim 54 for hand protection and grip by the hands or the ground or floor.

Front legs 60 hold the front of the board 10 4 inches off the ground or floor and are rotatably held in place by a pivot pin 41 or the like. The legs 60 are suitably made with 20-gauge sheet metal. Front legs 60 have reinforcing ribs 62. A lower recessed center section 64 forms two foot pads 66. Side edge folded hems 68 further add reinforcement to the front legs 60. When the legs 60 are folded up, they are flush with the bottom pan 24. The legs 40 are held in folded condition by friction. When the legs 60 are extended, they are folded out, they will rest “over-center” of the of the pivot pin 61 as top edge 70 abuts against the bottom pan 24. All non-hemmed edges have a steel reinforce rubber edging or trim 54 for hand protection and grip by the hands or the ground or floor.

Referring to FIGS. 2 through 6, the assembly of the cornhole board 10 may be appreciated. Upper pan 16 with side edges 14 are tightly closed over bottom pan 24 and side edges 22 forming hollow metal box 29. The box 29 is then placed in a press 76 that is typically heated although not necessary. The foam 88 is a mixed two part chemical injected by nozzle 82 which has moved the biased cap 80 out of the way to allow for foam injection. Great force is created as the foam 88 as the two chemicals react and are forced to expand (arrows 88) in an exothermic reaction. The force F of the press 76 and foam 88 expansion creates its own forces (arrows 88) that are countered by the force F of the press 76 creating flat surfaces on all sides and edges of what once was the hollow box 29. Once the injection is complete, the nozzle 82 is removed and the biased cap closes the foam ports 18 and 26. The foam 88 seals the upper and lower pans 16 and 24 together. The finished foamed cornhole board 10 has exception rigidity and light weight. The board 10 weighs just over 20 pounds with legs 40 and 60 and carrying handle 36. FIG. 7 is a cross sectional which shows the cross section of finished game board 10 showing PVC pipe slice 34, pans 16 and 24 and 6-inch bag hole 32 with smooth edges 35.

FIGS. 11 through 13 show playing surface or skin 12, with vinyl or magnet wraps 13 and 15 respectively which adds graphics, photos, images and the like to the game board 10. Guides 17 an can be added to the boards 10 to assist in directing bags to hole 32 for learning the game by children and novices.

Referring to FIGS. 14 through 16, heavy duty locking legs 90 and 92 may be appreciated. Legs 90 and 92 are made of steel tubes 94 welded to hinge base 96 which has a locking pin 98 to hold the legs 90 and 92 in playing position. Upon release of the pin 98 the legs may be folded into storage and transportation condition (arrow 99). These legs have been shown to hold up 750 pounds of dead weight.

The above explanations and showings of the present invention are for illustrative purposes. The true scope of the invention is defined by the following claims.