U.S. patent application number 14/909310 was filed with the patent office on 2016-06-23 for furniture article with concealed storage and removable panels.
The applicant listed for this patent is KITTRICH CORPORATION. Invention is credited to Carl Brock Brandenberg.
Application Number | 20160174700 14/909310 |
Document ID | / |
Family ID | 52432425 |
Filed Date | 2016-06-23 |
United States Patent
Application |
20160174700 |
Kind Code |
A1 |
Brandenberg; Carl Brock |
June 23, 2016 |
FURNITURE ARTICLE WITH CONCEALED STORAGE AND REMOVABLE PANELS
Abstract
A modular furniture system composed from reconfigurable
interlocking panels using corresponding slot and tab elements is
disclosed. The ready-to-assemble furniture system includes a
complementary arrangement of non-interlocking interior panels that
become secured into position through the means of interlocking
exterior side and end panels. The configuration of interlocking and
non-interlocking panels hides the joinery formed by the slot and
tab elements, and further utilizes selectively movable and/or
detachable panels to conceal the contents of storage
compartments.
Inventors: |
Brandenberg; Carl Brock;
(Fort Worth, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KITTRICH CORPORATION |
Pomona |
CA |
US |
|
|
Family ID: |
52432425 |
Appl. No.: |
14/909310 |
Filed: |
July 31, 2014 |
PCT Filed: |
July 31, 2014 |
PCT NO: |
PCT/US14/49113 |
371 Date: |
February 1, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61860282 |
Jul 31, 2013 |
|
|
|
Current U.S.
Class: |
5/93.1 ;
108/158.12; 108/25; 5/285 |
Current CPC
Class: |
A47B 83/04 20130101;
A47B 2230/0077 20130101; A47B 47/04 20130101; A47D 7/005 20130101;
A47D 7/007 20130101; A47C 19/005 20130101; A47B 2230/0085 20130101;
A47C 19/22 20130101; A47B 3/063 20170801 |
International
Class: |
A47B 3/06 20060101
A47B003/06; A47D 3/00 20060101 A47D003/00; A47C 19/00 20060101
A47C019/00; A47C 19/22 20060101 A47C019/22; A47B 83/04 20060101
A47B083/04; A47D 7/00 20060101 A47D007/00 |
Claims
1. A modular furniture system assembled from exterior and interior
panels having slot and tab joinery comprising: a first exterior
assembly composed of four interlocking panels; and a second
interior assembly composed of at least three non-interlocking
panels; wherein the first exterior assembly consists of at least
two symmetrical end panels that each have projecting interlocking
tab elements, and at least two side panels that each have
corresponding slots to interlock with the tab elements; wherein the
second interior assembly consist of at least two support panels
that extend vertically and in parallel relation with at least two
opposing side panels of the first exterior assembly, the support
panels having non-interlocking tab elements that protrude
orthogonally through the slots of at least two adjacent end panels
of the first exterior assembly; wherein the second interior
assembly further includes at least one horizontal panel having
non-interlocking tab elements that correspond with horizontal slots
formed within each support panel; and wherein the second interior
assembly additionally includes at least one horizontal panel having
tab elements that do not entirely extend through the horizontal
slots formed within each support panel.
2. The modular furniture system of claim 1, wherein the side panels
of the first exterior assembly hide the joinery formed from the
slot and tab elements of the second interior assembly.
3. The modular furniture system of claim 1, wherein an enclosable
storage compartment is formed by two opposing end panels of the
first exterior assembly, two opposing support panels of the second
interior assembly, and one horizontal panel of the second interior
assembly.
4. The modular furniture system of claim 3, wherein the enclosable
storage compartment is concealed with at least one detachable
panel.
5. The modular furniture system of claim 4, wherein at least one
detachable panel may engage the protruding tab elements of the two
opposing support panels of the second interior assembly, the tab
elements of which extend orthogonally beyond the end panels of the
first exterior assembly.
6. The modular furniture system of claim 1, wherein the
interlocking tab elements of the end panels of the first exterior
assembly are L-shaped, the tab elements having a raised undercut to
form an interference fit when fully inserted into a corresponding
slot of an adjacent exterior side panel.
7. The modular furniture system of claim 1, wherein the tab and
slot elements of the first exterior assembly are interlocked
together so as to form a right angle.
8. The modular furniture system of claim 1, wherein the four panels
of the first exterior assembly are of uniform thickness.
9. The modular furniture system of claim 1, wherein at least two
panels of the first exterior assembly are of uniform thickness.
10. The modular furniture system of claim 1, wherein the three
panels of the second interior assembly are equivalent in thickness
to the panels of the first exterior assembly.
11. The modular furniture system of claim 1, wherein at least two
panels of the second interior assembly are of uniform
thickness.
12. The modular furniture system of claim 1, wherein the exterior
or interior panels are fabricated from natural or manmade materials
selected from the group consisting of: solid hardwoods, solid
softwoods, plywood, particle board, MDF board, acrylic, plastic,
glass, and metal sheet stock.
13. The modular furniture system of claim 13, wherein the exterior
or interior panels are fabricated from birch plywood.
14. The modular furniture system of claim 13, wherein the panels
are finished differently on opposing sides.
Description
RELATED APPLICATION DATA
[0001] The present application claims priority to U.S. Provisional
Application No. 61/860,282 filed in the United States Patent Office
on Jul. 31, 2013, the entirety of which is hereby incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed toward ready-to-assemble
modular furnishings composed of interlocking planar materials. In
particular, the present invention relates to furniture fit together
from reconfigurable interlocking panels using corresponding slot
and tab elements to assemble or disassemble such components without
need for tools or fasteners. The modular furniture system also
includes the complementary arrangement of exterior and interior
panels to hide the joinery formed by the slot and tab elements, and
further utilizes selectively movable and/or detachable panels to
conceal the contents of storage compartments.
[0004] 2. Description of the Prior Art
[0005] The Internet has created exceptional growth in
business-to-consumer e-commerce sales over the last decade. The
distribution of products and services once only available at local
"brick and mortar" establishments has rapidly transitioned to
virtual on-line shopping portals that are now accessible to a
global audience. To be sure, the underlying activity of e-commerce
has not only changed the purchasing habits of consumers, but has
dramatically transformed the way in which manufactured goods are
delivered to end-users. In the case of home and office furnishings,
items that were once delivered pre-assembled from neighborhood
department stores are now shipped unassembled using flat-pack
methods from regional distribution facilities. Where individual
cartons containing flat-pack furnishings reduce the cubic volume
required to warehouse each product in a distribution center, along
with allowing for easier transport via parcel delivery services,
such furnishings consist of numerous components and hardware that
are often difficult and counterintuitive to assemble. Accordingly,
there is a need to provide an integrated approach to the design,
manufacture, distribution and assembly of furnishings that is
compatible with the current paradigm of order-fulfillment.
[0006] The primary disadvantage, inherent within prior art
ready-to-assemble furnishings, concerns the extensive use of
composite materials that consist of medium-density fiberboard (MDF)
clad with high-pressure decorative laminates. MDF, often called
"particle board," is composed of wood fiber glued under heat and
pressure to create a resilient grade of planar sheet stock.
Although considered a sustainable source in the fabrication of
furnishings, MDF board is a hygroscopic material that is prone to
dimensional changes depending on the relative humidity and air
temperature in the surrounding environment. When used in the
construction of furnishings, the bonded composition of MDF board
and high-pressure laminates may swell or delaminate when exposed to
moisture. Aside from the multilayered composite materials used in
the fabrication of flat-pack furnishings, exposed edges and
decorative laminated surfaces are known to chip or crack in final
assembly. Where high-pressure laminates are functional and durable,
decorative veneers of this type are produced from thermosetting
plastic resins that are formed and solidified under heat and
pressure, thereby increasing the rigidity while diminishing the
impact resistance of these materials. For this reason, the
compressive force exerted through the utilization of dowel pegs,
cam locks, and wood screws, found within the joinery and
pre-drilled apertures of the prior art, has caused fragments of
high-pressure laminates to break away from such ready-to-assemble
furnishings.
[0007] The use of interchangeable horizontal and vertical planar
components, having a corresponding arrangement of interlocking slot
and tab elements, is also known in the art to assemble a variety of
furnishings without the need for tools or fasteners. For example,
U.S. Pat. Nos. 6,769,369, 8,220,398, and 8,667,911, respectively
issued on Aug. 3, 2004, Jul. 17, 2012, and Mar. 11, 2014 to B.
Brandenberg, describe modular furniture systems composed of
interchangeable panels of uniform thickness. The planar components
are reversible and may be reconfigured into different furniture
pieces using a reciprocating pattern of interconnecting tabs,
slots, and grooves to secure the panels together.
[0008] Similarly, U.S. Pat. No. 8,590,976, issued on Nov. 26, 2013
to C. Davis, discloses ready-to-assemble furnishings comprised of
bendable panels that incorporate a series of interlocking joints
having slot and tab components. The constituent slot and tab
elements are disposed in misalignment to twist or displace the
planar configuration of adjoining panels so as to secure the joint
assembly without the use of additional fasteners. The modular
furniture system further includes the adaptable use of
interchangeable planar components within the same furniture
article, or to create different furniture pieces.
[0009] Modular furniture systems assembled from interlocking panels
have gained widespread acceptance within e-commerce channels of
distribution, and the products are primarily purchased by families
for use by young children. The simplicity of connecting and
dismantling component pieces to create new articles of furniture is
a fun and engaging activity that encourages curiosity and
involvement for young people. Until now, however, the interlocking
slot and tab elements used in prior art modular furniture systems
have been left exposed on the exterior surfaces of such items, and
has produced joinery that may be easily disengaged or tampered
with. The mating of interlocking panels produces apertures between
the fully assembled slot and tab elements, thereby creating pinch
points for small fingers. Accordingly, there is a need to provide a
modular furniture system that minimizes the exposure of slot and
tab joinery, while offering a product that is both educational and
easy to assemble.
[0010] The systems, methods, and inventions described in the
above-identified patent publications are found lacking in
disclosing an improved interlocking furniture system that reduces
the appearance of slot and tab elements on the exposed surfaces of
ready-to-assemble furnishings.
[0011] Accordingly, it is a principal object of the present
invention to provide a modular furniture system having a
complementary arrangement of interlocking panels that minimizes and
hides the slot and tab joinery on ready-to-assemble
furnishings.
[0012] It is a further object of the present invention to provide a
modular furniture system incorporating the use of exterior
interlocking panels that secure an arrangement of interior
non-interlocking panels when fully assembled.
[0013] It is yet another object of the present invention to provide
an arrangement of exterior interlocking panels incorporating the
use of tab elements having a raised undercut to form an
interference fit when fully inserted into a corresponding slot of
an adjacent exterior panel.
[0014] Finally, it an object of the present invention to provide a
modular furniture system having enclosable storage compartments
that may be concealed with an arrangement of selectively movable
and/or detachable panels.
SUMMARY OF THE INVENTION
[0015] The limitations of the background art discussed above are
overcome by the present invention. With this invention, an improved
modular furniture system, composed of a complementary arrangement
of interlocking and non-interlocking panels, minimizes the
appearance of joinery formed by corresponding slot and tab
elements. In a preferred embodiment, the modular furniture system
comprises a configuration of non-interlocking interior panels that
become secured into position through the means of interlocking
exterior side and end panels. The interlocking panels employ the
use of tab elements that produce an interference fit when fully
engaged with a corresponding slot; alternatively, the tab elements
may utilize a supplemental slot to provide a locking mechanism that
resists disassembly of the tab and slot joinery. The corresponding
use of the preferred tab and slot elements allows the assembly or
disassembly of the interlocking and non-interlocking panels without
the need for tools or fasteners. The modular furniture system is
further manufactured from a combination of planar components that
are interchangeable and symmetrical, and may be reconfigured into
different pieces of furniture. The assembly of exterior and
interior panels also forms enclosable storage compartments that may
be concealed through the use of movable and detachable panels.
[0016] Further objects and advantages of the present invention will
be apparent from the following description of the preferred
embodiments when considered in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a front perspective view of a children's play
table according to the present invention;
[0018] FIG. 2 is a front perspective view of the children's play
table of FIG. 1 showing a concealed storage area and detached panel
cover;
[0019] FIG. 3 is a front perspective view of the children's play
table of FIG. 1 showing a detached panel cover oriented in
attaching relation to a side panel of the present invention;
[0020] FIG. 4 is a front perspective view of the children's play
table of FIG. 1 showing a panel cover attached to a side panel of
the present invention;
[0021] FIG. 5 is an exploded view of the children's play table of
FIG. 1 showing the disassembled components of the present
invention;
[0022] FIGS. 6-7 are top plan views of the components of FIG. 5 on
pieces of planar sheet stock according to the modular furniture
system of the present invention.
[0023] FIGS. 8-9 illustrate the stacking and storage capabilities
of the modular furniture system of the present invention;
[0024] FIG. 10 is a front perspective view of a coffee table
according to an alternate embodiment of the present invention;
[0025] FIG. 11 is a front perspective view of the coffee table of
FIG. 10 showing a concealed storage area and hinged panel
covers;
[0026] FIG. 12 is a front perspective view of a desk having a
concealed storage area according to an alternate embodiment of the
present invention;
[0027] FIG. 13 is a front perspective view of a bed having
detachable panel covers and concealed storage areas according to an
alternate embodiment of the present invention;
[0028] FIG. 14 is a front perspective view of a crib having
detachable panel covers and concealed storage areas according to an
alternate embodiment of the present invention;
[0029] FIG. 15 is a perspective view of interchangeable panel
covers according to the present invention.
[0030] FIG. 16 is a rear perspective view illustrating the
interlocking slot and tab assembly of the prior art;
[0031] FIGS. 17a-17c are cross-sectional views of the assembly of a
slot and tab joint design with a curvature of the undercut of the
L-shaped tab, producing an interference fit according to a
preferred embodiment of the present invention;
[0032] FIGS. 18a-18c are cross-sectional views of the assembly of a
slot and tab joint design with a raised portion with a raised
portion on the undercut of the L-shaped tab, producing an
interference fit according to an alternate embodiment of the
present invention; and
[0033] FIGS. 19a-19c are cross-section views of the assembly of a
slot and tab joint design that provides a locking mechanism to
resist disassembly of the assembled joint according to an alternate
embodiment of the present invention.
[0034] Similar reference characters denote corresponding features
consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring to FIGS. 1-5 in the drawings, a children's play
table 10, made in accordance with the modular furniture system of
the present invention, is illustrated. The play table 10 is an
example of the type of ready-to-assemble furniture that can be fit
together from interlocking panels using corresponding slot and tab
elements without need for tools or fasteners. As explained herein,
the modular furniture system allows a user to assemble,
disassemble, and reconfigure a complementary arrangement of
exterior and interior panels that hide the joinery formed by the
slot and tab elements, while creating a large variety of
aesthetically pleasing furnishings that also provide concealed
storage areas. Furnishings assembled from the interchangeable and
reversible components of the present invention are ideally suited
for use where storage space is limited, and may include pieces such
as tables, desks, cribs, mattress foundations, and other items.
[0036] As illustrated in FIGS. 1-5, the play table 10 is preferably
rectangular and fit together from exterior side and end panels 11
and 12 having unequal adjacent sides that are located at right
angles to one another. The geometry of the longer side panels 11
are identical to one another, each having an arrangement of four
vertical slots 110 to receive connector tabs 120. The geometry of
the shorter end panels 12 are also identical to one another, each
having an arrangement of four L-shaped vertical interlocking
connector tabs 120, and each including a configuration of four
vertical slots 121 to receive the connector tabs 130 of interior
top supporting panels 13, and the connector tabs 150 of interior
bottom supporting panels 15. The four L-shaped vertical
interlocking connector tabs 120 also project outward and then
downward from each end panel 12 to form an interference fit when
inserted within the vertical slots 110 of side panels H. In a
preferred embodiment, and as shown as tab 120a in FIGS. 17a-17c,
the L-shaped tabs 120 of end panels 12 may utilize a locking bump
to ensure the secured assembly of the interlocking components
should the table 10 be lifted, tilted, or rotated upside down.
Alternatively, the exterior panels may be designed to produce a
table having four equal sides, but composed of side panels having a
greater length than the end panels, in order to compensate for the
slot and tab joinery used in the ready-to-assemble article.
[0037] With further reference to FIGS. 1-5, the play table 10 has a
complementary arrangement of two interior top supporting panels 13
that extend in parallel along side panels 11, and which are
situated in parallel along the opposing interior sides of the
table. The geometry of the top supporting panels 13 are identical
to one another, each having an arrangement of three horizontal
slots 131 to receive horizontal connector tabs 140 of top panel
14a. The top supporting panels 13 are maintained in position by
vertical connector tabs 130, each corresponding with vertical slots
121 of end panels 12, and each of which are designed to slide
easily into slots 121 without interlocking with end panels 12. In a
preferred embodiment, the connector tabs 130 protrude beyond the
planar exterior surfaces of end panels 12 to interface with
U-shaped notches 161 formed into the perimeter of detachable panels
16. The connector tabs 130 of top supporting panels 13 may be
shaped at one or both ends to suspend or store detachable panels 16
along the vertical surfaces of end panels 12. Alternatively, the
connector tabs 130 may not extend beyond the planar surfaces of end
panels 12.
[0038] In an additional embodiment, and as shown in FIGS. 1-5, the
play table 10 also has a complementary arrangement of two interior
bottom supporting panels 15 that extend in parallel along side
panels 11, and which are situated in parallel along the opposing
interior sides of the table. The geometry of the bottom supporting
panels 15 are identical to one another, each having an arrangement
of three horizontal slots 151 to receive horizontal connector tabs
140 of bottom panel 14b. The bottom supporting panels 15 are
maintained in position by vertical connector tabs 150, each
corresponding with vertical slots 121 of end panels 12, and each of
which are designed to slide easily into slots 121 without
interlocking with end panels 12. In a preferred embodiment, the
connector tabs 150 do not protrude beyond the planar exterior
surfaces of end panels 12. Alternatively, the connector tabs 150
may protrude beyond the planar exterior surfaces of end panels 12
to interface with a supplemental pair of U-shaped notches formed
within the perimeter of detachable panels 16 (not shown). The
connector tabs 150 of bottom supporting panels 15 may be shaped at
one or both ends to help suspend or store detachable panels 16
along the vertical surfaces of end panels 12.
[0039] In a preferred embodiment, and as further illustrated in
FIG. 5, the geometry of the horizontally oriented top and bottom
panels 14a and 14b are identical to one another, with each having
an arrangement of six horizontal connector tabs 140, which either
insert into the horizontal slots 131 of the two interior top
supporting panels 13, or into the horizontal slots 151 of the two
interior bottom supporting panels 15. The horizontal connector tabs
140 of either top or bottom panels 14a or 14b, are designed to
easily slide into horizontal slots 131 or 151, without interlocking
with supporting panels 13 or 15, respectively. In an alternate
embodiment, the four interior supporting panels 13 and 15 may
consist of just two vertically oriented interior support panels
(not shown) that extend in parallel along side panels 11, and which
are situated in parallel along the opposing interior sides of play
table 10. Each vertically oriented interior support panel has an
arrangement of six horizontally oriented slots that are positioned
in similar relation to the horizontal slots 131 and 151, of
supporting panels 13 and 15, in the preferred embodiment. The
horizontal tabs 140 of either top or bottom panels 14a or 14b are
similarly designed to slide into the horizontal slots formed within
each vertically oriented interior support panel without
interlocking. Moreover, the two interior support panels of the
alternate embodiment may be similarly maintained in position by
vertical connector tabs that correspond with the vertical slots 121
of end panels 12, each of which are designed to slide easily into
slots 121 without interlocking with end panels 12, and each of
which are analogous in shape to the vertical connector tabs 130 and
150 of interior support panels 13 and 15, respectively. The
horizontal connector tabs 140 of either the preferred or alternate
embodiment do not extend beyond the outermost planar surfaces of
the interior support panels, to allow the joinery formed by the
slot and tab elements to remain hidden behind side panels 11.
[0040] Referring once again to FIGS. 1-5, the play table 10 is
assembled from a complementary arrangement of non-interlocking
interior panels 13, 14a, 14b and 15, which become secured into
position through the means of interlocking exterior side and end
panels 11 and 12. In a preferred embodiment, the exterior side and
end panels 11 and 12 are of uniform thickness; alternatively, the
arrangement of four vertical slots 110, located within each side
panel 11, may be adjusted to accommodate a dissimilar thickness of
end panels 12 in comparison to the thickness of side panels 11. The
non-interlocking interior panels 13, 14a, 14b and 15 may be of the
same thickness as exterior side and end panels 11 and 12. In a
preferred embodiment, the interior top and bottom supporting panels
13 and 15 must be of equal thickness to each other, but may be of
dissimilar thickness in comparison to the exterior side and end
panels 11 and 12. Additionally, the top and bottom supporting
panels 13 and 15 may be of dissimilar thickness in relation to the
thickness of interior top and bottom panels 14a and 14b. The
exterior and interior panels used in the assembly of the preferred
and alternate embodiments of present invention may be composed of
similar or dissimilar planar materials. For example, play table 10
may consist of natural or composite wood sheets such as: solid
hardwood or softwood; plywood; particle board; or MDF board.
Moreover, acrylic, plastic, glass or metal sheets may also be
utilized in the production of the panels, but the use of
pre-finished melamine-coated plywood and high quality birch plywood
is most preferred. The exterior and interior panels may also be
finished differently on opposing sides to allow the user to choose
the appearance of the assembled item.
[0041] As further depicted in FIGS. 1-5, an upper enclosable
storage compartment and lower accessible shelving area of play
table 10 are formed through the assembly of the exterior and
interior panels of the present invention. The volume of the upper
enclosable storage compartment is defined through the assembly of
the two interior supporting top panels 13, the horizontally
oriented interior top panel 14a, and the end panels 12. The storage
compartment may also be partitioned into smaller sections through
the use of halved joint dividers. As seen in FIG. 7, the dividers
18 and 19 may be produced concurrently with the exterior and
interior panels of play table 10. The upper storage volume may be
enclosed through the use of detachable and selectively movable
panels 16 and 17, which are maintained in sliding relation along
the facing edge portions of the top supporting panels 13. The lower
accessible shelving area of play table 10 is similarly defined
through the assembly of the two bottom interior supporting panels
15, the horizontally oriented interior bottom panel 14b, and the
exterior end panels 12.
[0042] As illustrated in FIGS. 1-5 and 15, the present invention
incorporates the use of three detachable panels, with two smaller
panels 16 located adjacent to a larger detachable panel 17.
Although fewer or additional panels may be used to enclose the
upper storage compartment of play table 10, the smaller panels 16
may be interchanged with panels 26a, 36 and 46, each having
U-shaped notches 161, 261, 361 and 461, respectively, which are
formed within the perimeter of each detachable panel. The U-shaped
notches 161, 261, 361, or 461, may also consist of blind cutouts
that do not extend through the thickness of the detachable cover
panels (not shown). The detachable panels 16, 36 and 46, may
incorporate openings 160, 362, or 460 to facilitate easy lifting by
hand; alternatively, the geometry of the panels may also include
diagonal edges 262 to assist in removal. With further reference to
FIGS. 10-11, and by way of example, two or more of the detachable
cover panels 26b and 27 may be attached to one another using one or
more hinge mechanisms 263, thereby preventing removal of an
individual panel but allowing the detachable panels to pivot in
relation to one another.
[0043] Referring now to FIGS. 6-7 in the drawings, the geometry for
all of the required component pieces of play table 10 are
illustrated on 48-inch by 72-inch panels for production on a
computer numerical control (CNC) router system. The router pattern
layouts of work pieces 11, 12, 13, 14a, 14b, 15, 16, 17, 18, and 19
are detailed, and are preferably fabricated from planar materials
of uniform thickness to minimize the number of different machining
processes required for manufacture. Such layouts also ensure that
material is efficiently used to manufacture the components of the
present invention. This feature has the following advantages: (1)
no post-machining assembly is performed, so the amount of material
handling and number of required machining operations is minimized,
reducing the total cost of manufacture; (2) final components can be
produced from raw material in one machining step; (3) the planar
design makes machining very suitable for two-axis machining
processes such as computer numerical control (CNC) routers; (4)
flat pieces may be packed and shipped using flat-pack methods which
minimizes the total size of the shipping package (see FIGS. 8 and
9); and (5) flat pieces allow for more compact storage by the user
before assembly or after disassembly. It should be understood that
other layouts for furniture articles composed of variable planar
thicknesses may also be used.
[0044] The preferred and alternate embodiments of the present
invention may be utilized to make other furniture articles. For
example, as shown in FIGS. 10-11, the provisions used in the
fabrication and assembly of play table 10 may be incorporated to
make a coffee table 20. Like the play table, the coffee table 20 is
generally rectangular and fit together from exterior side and end
panels 21 and 22 having adjacent sides that are located at right
angles to one another. The geometry of the longer side panels 21
are identical to one another, each having an arrangement of four
vertical slots 210 to receive connector tabs 220. The geometry of
the shorter end panels 22 are also identical to one another, each
having an arrangement of four L-shaped vertical interlocking
connector tabs 220, and each including a configuration of two
vertical slots 221 to receive connector tabs 230 of interior
support panels 23. Unlike play table 10, the coffee table 20 has
only one set of interior panels 23 to support only one interior
horizontal panel 24. The four L-shaped vertical interlocking
connector tabs 220 also project outward and then downward from each
end panel 22 to form an interference fit when inserted within the
vertical slots 210 of side panels 21. In a preferred embodiment,
and as depicted as tab 120a in FIGS. 17a-17c, the L-shaped tabs 220
of end panels 22 may utilize a locking bump to ensure the secured
assembly of the interlocking components should the coffee table 20
be lifted, tilted, or rotated upside down. Alternatively, the
exterior panels may be designed to produce an end table (not shown)
having four equal sides, but composed of side panels having a
greater length than the end panels, in order to compensate for the
slot and tab joinery used in the ready-to-assemble article. As
further seen in FIGS. 10-11, the coffee table 20 implements the
same method of assembly as play table 10, using a complementary
arrangement of non-interlocking panels 23 and 24, which become
secured into position through the means of interlocking side and
end panels 21 and 22. The non-interlocking panels 23 and 24 are
also identical in geometry as non-interlocking top supporting
panels 13, along with panels 14a or 14b, of play table 10. In a
preferred embodiment, the exterior side and end panels 21 and 22
are of uniform thickness, although the arrangement of four vertical
slots 210, located in each side panel 21, may be adjusted to
accommodate a dissimilar thickness of end panels 22 in comparison
to the thickness of side panels 21. The non-interlocking panels 23
and 24 may also be of the same or dissimilar thickness as exterior
side and end panels 21 and 22.
[0045] As further illustrated in FIG. 11, an enclosable storage
compartment of coffee table 20 is formed through the assembly of
the exterior and interior panels of the present invention. The
volume of the storage compartment is defined through the assembly
of the two interior supporting panels 23, the horizontally oriented
interior panel 24, and the end panels 22. The storage compartment
may also be partitioned into smaller sections through the use
dividers (not shown). The storage volume may be enclosed through
the use of detachable and selectively movable panels 26b and 27,
which are maintained in sliding relation along the facing edge
portion of the supporting panels 23. As in the embodiments
disclosed for play table 10, the coffee table 20 incorporates the
use of three detachable panels, with two smaller panels 26b located
adjacent to a large detachable panel 27, which is positioned in the
middle of the coffee table. Although fewer or additional panels may
be used to enclose the storage compartment, the smaller panels 26b
may be interchanged with panels 16, 26a, 36 or 46 seen in FIG. 15;
alternatively, the detachable panels 26b and 27 may be attached to
one another using a hinge mechanism 263 to pivot in relation to one
another.
[0046] With reference to FIG. 12 in the drawings, the planar
components of the present invention may be scaled to produce a
variety of different furnishings to suit any number of
environments. For example, the height of the exterior side and end
panels in coffee table 20 may be increased to create a desk 30;
alternatively, the design may be re-scaled to produce a workbench
or tool bench with a storage compartment. Similar to the coffee
table, desk 30 is also rectangular and fit together from exterior
side and end panels 31 and 32, respectively, having adjacent sides
that are located at right angles to one another. The geometry of
the longer side panels 31 are identical to one another, each having
an arrangement of four vertical slots 310 to receive connector tabs
320. The geometry of the shorter end panels 32 are also identical
to one another, each having an arrangement of four L-shaped
vertical interlocking connector tabs 320, and each including a
configuration of two slots (not shown) to receive connector tabs
330 of interior supporting panels 33. Like coffee table 20, the
desk 30 has only one set of interior panels 33 to support only one
interior horizontal panel 34. The four L-shaped vertical
interlocking connector tabs 320 also project outward and then
downward from each end panel 32 to form an interference fit when
inserted within the vertical slots 310 of side panels 31. In a
preferred embodiment, and as shown as tab 120a in FIGS. 17a-17c,
the L-shaped tabs 320 of end panels 32 may utilize a locking bump
to ensure the secured assembly of the interlocking components
should the desk 30 be lifted, tilted, or rotated upside down. The
desk 30 implements the same method of assembly as coffee table 20,
using a complementary arrangement of non-interlocking panels 33 and
34, which become secured into position through the means of
interlocking side and end panels 31 and 32. The non-interlocking
panels 33 and 34 are also identical in geometry as non-interlocking
panels 23 and 24 of coffee table 20. In a preferred embodiment, the
exterior side and end panels 31 and 32 are of uniform thickness,
although the arrangement of four vertical slots 310, located in
each side panel 31, may be adjusted to accommodate a dissimilar
thickness of end panels 32 in comparison to the thickness of side
panels 31. The non-interlocking panels 33 and 34 may also be of the
same or dissimilar thickness as exterior side and end panels 31 and
32.
[0047] As shown in FIG. 12, an enclosable storage compartment of
desk 30 is formed through the assembly of the exterior and interior
panels of the present invention. The volume of the storage
compartment is defined through the assembly of the two interior
supporting panels 33, the horizontally oriented interior panel 34,
and the end panels 32. The storage compartment may also be
partitioned into smaller sections through the use of dividers (not
shown). The storage volume may be enclosed through the use of
detachable and selectively movable panels 36 and 37, which are
maintained in sliding relation along the facing edge portion of the
interior supporting panels 33. As in the embodiments disclosed for
the coffee table 20, the desk 30 incorporates the use of three
detachable panels, with two smaller panels 36 located adjacent to a
larger detachable panel 37, which is positioned in the middle of
the desk 30. The two detachable panels 36 may be modified with slot
cuts 371 to accommodate the pass through of computer cables, the
panels 36 each have U-shaped notches 361 formed within the
perimeter of each detachable panel so that they may be suspended by
connector tabs 330 for storage. The panels 36 may be interchanged
with panels 16, 26a, or 46 seen in FIG. 15. Alternatively, the
detachable panels 36 and 37 may be attached to one another using a
hinge mechanism (not shown) to pivot in relation to one
another.
[0048] The geometry of the interlocking components of the present
invention may also be modified to create furniture articles having
multiple storage areas, which are ideally suited for use within
environments where storage space is limited. For example, and as
illustrated in FIG. 13, the panels used in the fabrication of play
table 10, shown in FIGS. 1-5, may be elongated to make a mattress
foundation for a bed. Like the play table, the mattress foundation
40 is generally rectangular and fit together from exterior side and
end panels, however, in this embodiment the end panels 12 of play
table 10 have been extended to make side rails 42, and the side
panels 11 of play table 10 have been adapted to make head and
footboard components 41a, 41b and 41c. The geometry of the head and
footboard components 41a, 41b, and 41c are not identical to one
another, but panels 41a and 41c each have an arrangement of four
vertical slots 410 to receive connector tabs 420 of side rails 42.
The geometry of side rails 42 are identical to one another, each
having horizontally oriented openings that provide access to a
storage area within the mattress foundation 40, and each having an
arrangement of four L-shaped vertical interlocking connector tabs
420. The side rails 42 are also fabricated with an upper
configuration of vertical slots (not shown) to receive the
connector tabs 430 of six interior top supporting panels (not
shown), which provide reinforcement for removable panels 46. Side
rails 42 additionally include a bottom configuration of two lower
vertical slots (not shown), located near the head and footboard of
the bed, which interface with two interior bottom supporting panels
45, and extend in parallel along the head and footboard panels 41b
and 41c. The four L-shaped vertical interlocking connector tabs
420, of each side rail 42, also project outward and then downward
to form an interference fit when inserted within the vertical slots
410 of panels 41a and 41c. In a preferred embodiment, and
exemplified as tab 120b in FIGS. 18a-18c, the L-shaped tabs 420 of
side rails 42 may utilize a locking bump to ensure the secured
assembly of the interlocking components.
[0049] As further shown in FIG. 13, enclosable storage compartments
of the mattress foundation 40 are formed through the assembly of
the exterior and interior panels of the present invention. The
volume of the storage compartments are defined through the assembly
of bottom supporting panels 45, the horizontally oriented interior
panel 44, the head and footboard components 41b and 41c, and
removable panels 46. The storage volume may be enclosed through the
use of detachable panels 16, each having an opening 160 to
facilitate easy lifting by hand. Moreover, the detachable panels 16
each have U-shaped notches 161 formed within the perimeter of each
panel, which are used to removably interface with vertical
connector tabs 430. The storage volume may also be accessed through
removable panels 46 that also provide support for a box spring and
mattress. The panels 46 additionally feature the use of U-shaped
notches 461, along with openings 460, to assist in the handling of
the removable components.
[0050] Referring now to FIG. 14 in the drawings, the modular
components of the mattress foundation 40 may be scaled to produce a
crib. Like the mattress foundation, the crib 50 is generally
rectangular and fit together from side rail panels 52 along with
head and footboard panels 51. The geometry of the head and
footboard panels 51 are identical to one another, each having an
arrangement of four vertical slots 510a to receive connector tabs
520a, and each having a configuration of four vertical slots 510b
to receive connector tabs 520b. The geometry of side rail panels 52
are also identical to one another, each having an arrangement of
four L-shaped vertical interlocking connector tabs 520a, which
project outward and then downward to form an interference fit when
inserted within the vertical slots 510a of head and footboard
panels 51. In a preferred embodiment, and as exemplified as tab
120c in FIGS. 19a-19c, the L-shaped tabs 520a may utilize a
separate slot 741 for interlocking panels 51 and 52, respectively,
to provide a safety mechanism that resists disassembly of the joint
in reverse order of assembly. The corresponding configuration of
vertical slots 510b and connector tabs 520b, the interior support
rails of which are designed to raise or lower a mattress (not
shown), may also incorporate the safety mechanism disclosed in
FIGS. 19a-19c. The side rail panels 52 are also fabricated with an
upper arrangement of four vertical slots (not shown) to receive
connector tabs 530 of two interior top supporting panels (not
shown), and two interior bottom supporting panels 55, which extend
in parallel along the head and footboard panels 51.
[0051] As further shown in FIG. 14, enclosable storage compartments
of crib 50 are formed through the assembly of the exterior and
interior panels of the present invention. The volume of the storage
compartments are defined through the assembly of bottom supporting
panels 55, the horizontally oriented interior panel 54, the head
and footboard panels 51, and an upper mattress support panel (not
shown). The storage volume may be enclosed through the use of
detachable panels 16, each having an opening 160 to facilitate easy
lifting by hand. Moreover, the detachable panels 16 each have
U-shaped notches 161 formed within the perimeter of each panel,
which are used to removably interface with vertical connector tabs
530. [0052] The combination of the exterior and interior panels of
crib 50, along with other furnishings assembled according to the
present invention, hides the joinery formed by the slot and tab
elements which, heretofore, have been left exposed on the exterior
surfaces of prior art modular furniture systems. As illustrated in
FIG. 16, slot and tab elements of the prior art have produced
joinery that may be easily disengaged or tampered with by young
children. For example, the mating of panels 61, 62, and 64, through
the means of vertical slot and tab joinery 610 and 620, along with
horizontal slot and tab joinery 630 and 640, have produced exposed
apertures between the assembled slot and tab elements that are
pinch points for young fingers. The complementary arrangement of
exterior and interior panels to hide such joinery, along with the
preferred use of the slot and tab means described below, minimizes
the existence of pinch points in the assembly of interlocking
panels.
[0052] In the following descriptions, the term "design" is
generally used to refer to the general shape of the members being
assembled to form the slot and tab joinery, but does not refer to
the exact dimensions of the shapes. "Specification" is generally
used to refer to a particular implementation of a joint design,
where the exact shape dimensions and tolerances need be specified
for a particular material in a specified range of acceptable
thickness.
[0053] In a preferred embodiment, the end panels 12 as shown on
FIG. 1 may utilize an L-shaped tab 120 having a locking bump to
keep the table securely assembled should the table be lifted,
tilted or rotated on its side or upside down. The locking bump
prevents the L-shaped tab 120 from being easily disengaged by
relying on the flexure of the mating panel to provide resistance
against the L-shaped tab being urged sideways. As illustrated in
FIGS. 17a-17c, and as further explained in U.S. Pat. Nos. 8,220,398
and 8,667,911, the interference bump on the undercut of an L-shaped
tab 120a produces a joint with a loose fit at the start of
engagement, and an interference fit once the material around the
slot 110 has engaged the bump. In this joint design, the bump is
positioned to provide an interference fit over the majority of the
engagement length of the joint. For any material thickness in the
range between the minimum and maximum thickness specified for a
particular joint specification, this design provides for easy
alignment of a tab 120a and slot 110, and allows the undercut of
the L-shaped tab 120a to begin engaging the material around the
slot 110 before any significant assembly force is required, making
part alignment during assembly easier for the user. Depending on
the thickness, elasticity and compressibility of the material,
assembly force will increase as the material around the slot
engages the bump, but will remain uniform throughout the completion
of joint assembly until the material around the slot 110 fully
engages the crotch of the tab 120a. This joint design yields a
securely assembled joint and is well suited to harder materials
such as birch plywood, because the material thickness tolerances
dictated by manufacturing standards such as Gosstandart (GOST), and
the elasticity and compressibility of the material match well with
the tolerances and interference characteristics of this particular
joint design. It should be understood that the bump does not have
to be integral to the panel material, but could be produced by an
insert made of wood, plastic, metal, or other material. Inserts
made of soft materials such as wood or plastic may deform more in
an interference fit situation than harder materials like metal,
causing less permanent disfiguration to the mating panel. FIGS.
17a-17c depict the use of a bumped surface as part of an L-shaped
tab 120a. FIG. 17a illustrates a close fit, while FIGS. 17b and 17c
detail an interference fit. Graphs 625, 627, and 629 generally
illustrate the assembly force required. In FIGS. 17a, 17b, and 17c,
the tab 120a is a single specification. The material that is
utilized to form the slot varies in thickness. FIG. 17a utilizes a
material for the slot that has a thickness 11a. FIG. 17b utilizes a
material for the slot that has a thickness of 11b. FIG. 17c
utilizes a material for the slot that has a thickness of 11e.
[0054] In an alternate embodiment, and with further reference to
U.S. Pat. Nos. 8,220,398 and 8,667,911, side rails 42, shown in
FIG. 13, may utilize and L-shaped tab 420 having a locking bump
that is positioned on the undercut to produce a joint with a loose
fit at the start of engagement, and an interference fit once the
material around the slot 410 has engaged the bump. As shown in
FIGS. 18a-18c, the bump is positioned to provide an interference
fit over a fraction of the engagement length of the joint, hence
minimizing the distance over which force must be exerted to fully
assemble the joint. For any material thickness in the range between
the minimum and maximum thickness specified for a particular joint
specification, this design provides for easy alignment of a tab
120b and slot 110, and allows the undercut of the L-shaped tab 120b
to begin engaging the material around the slot 110 before any
significant assembly force is required, making part alignment
during assembly easier for the user. Depending on the thickness,
elasticity and compressibility of the material, assembly force will
increase as the material around the slot engages the bump, but will
remain uniform throughout the completion of joint assembly until
the material around the slot 110 fully engages the crotch of the
tab 120b. This joint design yields a securely assembled joint and
is well suited to harder materials such as birch plywood, because
the material thickness tolerances dictated by manufacturing
standards such as GOST, and the elasticity and compressibility of
the material match well with the tolerances and interference
characteristics of this particular joint design. FIGS. 18a-18c
illustrate the use of a bumped surface as part of an L-shaped tab
120b. FIG. 18a illustrates a close fit, while FIGS. 18b and 18c
depict an interference fit. Graphs 631, 633, and 635 generally
illustrate the assembly force required. In FIGS. 18a, 18b, and 18c,
the tab 120b is a single specification. The material that is
utilized to form the slot varies in thickness. FIG. 18a utilizes a
material for the slot that has a thickness 11a. FIG. 18b utilizes a
material for the slot that has a thickness of 11b. FIG. 18c
utilizes a material for the slot that has a thickness of 11e.
[0055] In yet a further alternate embodiment, and with additional
reference to U.S. Pat. Nos. 8,220,398 and 8,667,911, the side rail
52 of FIG. 14 may utilize a separate slot 741 for locking the
planar components to assemble the joint. As exemplified in FIGS.
19a-19c, the separate slot 741 can be located anywhere on the panel
and does not have to be near an existing tab of a slot 110. FIGS.
19a and 19b detail a tab 120c inserted into a slot 110 with
surfaces S5 and T5 in engagement. FIG. 19b shows a tab 120c moved
relative to a slot 110 with surface T1 of tab 120c making contact
with surface S1, and surface S2 making contact with raised portion
743 of surface T2. The design causes the mating panel to flex
during assembly, and then snap into the slot to provide a locking
mechanism that resists disassembly of the joint in reverse order of
assembly. FIG. 19c demonstrates a slot 110 and tab 120c fully
engaged and locked into position by surface S5 of slot 741 engaging
the shoulder of raised portion 743. The shape of the raised portion
743 may be varied to change the resistance characteristics of the
locking mechanism. By making the raised portion 743 higher, the
amount of force required to disassemble the joint can be
increased.
[0056] Even though numerous characteristics and advantages of the
present invention has been set forth in the foregoing description,
together with details of the structure and function of the
preferred embodiments, the above disclosure is illustrative only.
Changes may be made in detail, especially in matters of shape, size
and arrangement of parts within the principles of the invention to
the full extent indicated by the broad and general meaning of the
terms in which the appended claims are expressed.
* * * * *