U.S. patent application number 16/255162 was filed with the patent office on 2019-05-23 for furniture system and related methods.
The applicant listed for this patent is Sauder Woodworking Co.. Invention is credited to Marvin K. Burnett.
Application Number | 20190150611 16/255162 |
Document ID | / |
Family ID | 66534052 |
Filed Date | 2019-05-23 |
View All Diagrams
United States Patent
Application |
20190150611 |
Kind Code |
A1 |
Burnett; Marvin K. |
May 23, 2019 |
FURNITURE SYSTEM AND RELATED METHODS
Abstract
A leg includes an outer surface, an inner surface, a first wall,
a second wall, a first seam, and a second seam. The inner surface
is opposite the outer surface. The first wall extends from the
outer surface to the inner surface. The second wall is coupled to
the first wall and extends from the outer surface to the inner
surface. The first seam is formed in the inner surface. The second
seam is spaced apart from the first seam and formed in the inner
surface. The second seam forms a first non-parallel angle with the
first seam and a second non-parallel angle with the first wall.
Inventors: |
Burnett; Marvin K.;
(Archbold, OH) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Sauder Woodworking Co. |
Archbold |
OH |
US |
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|
Family ID: |
66534052 |
Appl. No.: |
16/255162 |
Filed: |
January 23, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16233669 |
Dec 27, 2018 |
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16255162 |
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15657390 |
Jul 24, 2017 |
10201226 |
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16233669 |
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15407921 |
Jan 17, 2017 |
10034543 |
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15657390 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B 47/0083 20130101;
A47B 2230/0085 20130101; A47B 2230/0029 20130101; A47B 2230/0059
20130101; Y10T 156/1056 20150115; A47B 7/00 20130101; A47B 87/0215
20130101; Y10T 156/1051 20150115; A47B 91/00 20130101; A47B 96/021
20130101; A47B 96/202 20130101; A47B 43/02 20130101; A47B 47/0091
20130101; A47B 2200/002 20130101; A47B 2230/0055 20130101; A47B
87/0207 20130101; A47B 47/0066 20130101; A61G 7/0507 20130101; A47B
47/06 20130101; A47F 5/112 20130101; F16B 2012/403 20130101; A47B
55/06 20130101 |
International
Class: |
A47B 47/00 20060101
A47B047/00; A47B 47/06 20060101 A47B047/06; A47B 55/06 20060101
A47B055/06; A47B 87/02 20060101 A47B087/02; A47F 5/11 20060101
A47F005/11; A47B 43/02 20060101 A47B043/02 |
Claims
1. A leg comprising: an outer surface; an inner surface opposite
the outer surface; a first wall extending from the outer surface to
the inner surface; a second wall coupled to the first wall and
extending from the outer surface to the inner surface; a first seam
formed in the inner surface; and a second seam spaced apart from
the first seam and formed in the inner surface, the second seam
forming a first non-parallel angle with the first seam and a second
non-parallel angle with the first wall.
2. The leg of claim 1, wherein the first non-parallel angle is
equal to the second non-parallel angle.
3. The leg of claim 2, wherein the first non-parallel angle is five
degrees.
4. The leg of claim 1, wherein the inner surface defines a
multi-sided pyramidal shape.
5. The leg of claim 1, wherein the first seam includes a first
proximal portion and a first distal portion extending from the
first proximal portion, and wherein the first proximal portion
forms a third non-parallel angle with the first distal portion.
6. The leg claim 5, wherein the second seam includes a second
proximal portion and a second distal portion extending from the
second proximal portion, and wherein the second proximal portion
forms a fourth non-parallel angle with the second distal
portion.
7. The leg of claim 6, wherein the outer surface includes a
proximal outer portion and a distal outer portion, the proximal
outer portion extending between the first proximal portion and the
second proximal portion, the distal outer portion extending between
the proximal outer portion, the first distal portion, and the
second distal portion, and wherein the proximal outer portion forms
a fifth non-parallel angle with the distal outer portion.
8. The leg of claim 7, wherein the proximal outer portion defines a
pyramidal cross-sectional shape.
9. The leg of claim 8, wherein the distal outer portion defines a
shape having a uniform cross-sectional area.
10. The leg of claim 1, wherein the outer surface defines a
pyramidal shape.
11. A leg extending from a proximal end to a distal end, the leg
comprising: a first wall extending from the proximal end to the
distal end; a second wall coupled to the first wall and extending
from the proximal end to the distal end; a first seam spaced apart
from the first wall and the second wall and extending from the
proximal end to the distal end; a second seam spaced apart from the
first seam, the first wall, and the second wall and extending from
the proximal end to the distal end; and an outer surface including
a first segment extending between the first wall and the first
seam, a second segment extending between the first seam and the
second seam, and a third segment extending between the second seam
and the second wall, wherein the first segment, the second segment,
and the third segment define a pyramidal cross-sectional shape
extending from the proximal end to the distal end.
12. The leg of claim 11, wherein the second seam forms a first
non-parallel angle with the first seam and a second non-parallel
angle with the first wall.
13. The leg of claim 12, wherein the first non-parallel angle is
equal to the second non-parallel angle.
14. The leg of claim 13, wherein the first non-parallel angle is
five degrees.
15. The leg of claim 11, further comprising an inner surface
opposite the outer surface and defining a multi-sided pyramidal
shape.
16. The leg of claim 11, wherein the first seam includes a first
proximal portion and a first distal portion extending from the
first proximal portion, and wherein the first proximal portion
forms a first non-parallel angle with the first distal portion.
17. The leg of claim 16, wherein the second seam includes a second
proximal portion and a second distal portion extending from the
second proximal portion, and wherein the second proximal portion
forms a second non-parallel angle with the second distal
portion.
18. The leg of claim 17, wherein the outer surface includes a first
distal outer portion extending from the first segment, a second
distal outer portion extending from the second segment, and a third
distal outer portion extending from the third segment, and wherein
the first segment forms a third non-parallel angle with the first
distal outer portion.
19. The leg of claim 18, wherein the first, second, and third
distal outer portions define a shape having a uniform
cross-sectional area.
20. A leg comprising a substrate including a first proximal
segment, a second proximal segment, and a third proximal segment,
the second proximal segment hingedly coupled to the first proximal
segment along a first seam, the third proximal segment hingedly
coupled to the second proximal segment along a second seam, the
first seam forming a first non-parallel angle with the second
seam.
21. The leg of claim 20, wherein the first proximal segment is
coupled to the third proximal segment along a third seam forming a
second non-parallel angle with the second seam, the first
non-parallel angle being equal to the second non-parallel
angle.
22. The leg of claim 21, wherein the first non-parallel angle is
five degrees.
23. The leg of claim 20, wherein the first proximal segment
includes a first proximal outer surface, the second proximal
segment includes a second proximal outer surface, and the third
proximal segment includes a third proximal outer surface, and
wherein the first, second, and third proximal outer surfaces define
a varying cross-sectional area.
24. The leg of claim 23, wherein the varying cross-sectional area
defines a pyramid.
25. The leg of claim 20, further comprising: a first distal segment
hingedly coupled to the first proximal segment and having a first
distal wall and a second distal wall parallel to the first distal
wall; a second distal segment hingedly coupled to the second
proximal segment and having a third distal wall and a fourth distal
wall parallel to the third distal wall; and a third distal segment
hingedly coupled to the third proximal segment and having a fifth
distal wall and a sixth distal wall parallel to the fifth distal
wall.
26. The leg of claim 25, wherein the first distal wall is coupled
to the sixth distal wall, the second distal wall is coupled to the
third distal wall, and the fourth distal wall is coupled to the
fifth distal wall.
27. The leg of claim 25, wherein the first distal segment includes
a first distal outer surface, the second distal segment includes a
second distal outer surface, and the third distal segment includes
a third distal outer surface, and wherein the first, second, and
third distal outer surfaces defining a uniform cross-sectional
area.
28. The leg of claim 27, wherein the uniform cross-sectional area
defines a rectangle.
29. The leg of claim 25, further comprising a polyurethane adhesive
disposed between the first distal segment and the first proximal
segment.
30. The leg of claim 25, further comprising an endcap coupled to
one or more of the first distal segment, the second distal segment,
or the third distal segment, such that the endcap, the first distal
segment, the second distal segment, and the third distal segment
define an enclosed leg.
31. The leg of claim 20, wherein the substrate include a base layer
and a laminate layer.
32. The leg of claim 31, wherein the base layer defines a
channel.
33. The leg of claim 20, wherein the first proximal segment is
coupled to the third proximal segment along a third seam forming a
second non-parallel angle with the first seam.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This U.S. patent application is a continuation-in-part of
U.S. patent application Ser. No. 16/233,669, filed on Dec. 27,
2018, which is a divisional of U.S. patent application Ser. No.
15/657,390, filed on Jul. 24, 2017, which is a continuation-in-part
of U.S. patent application Ser. No. 15/407,921, filed on Jan. 17,
2017, now U.S. Pat. No. 10,034,543, issued on Jul. 31, 2018. The
disclosures of these prior applications are considered part of the
disclosure of this application and are hereby incorporated by
reference in their entireties.
FIELD
[0002] The present disclosure relates to a system and method for
constructing an article, and more particularly to articles having a
folded construct.
BACKGROUND
[0003] This section provides background information related to the
present disclosure and is not necessarily prior art.
[0004] Laminated substrates are often used to manufacture various
types of furniture and fixtures for homes and offices. For example,
countertops, drawer boxes, speaker boxes, and other items are often
manufactured from wood, or a wood composite, having a polymer
laminate.
[0005] While known systems and methods for constructing articles
such as bed rails, ceiling panels, and furniture legs have proven
useful for their intended purposes, a need for continuous
improvement in the pertinent art remains.
SUMMARY
[0006] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0007] One aspect of the disclosure provides a leg. The leg
includes an outer surface, an inner surface, a first wall, a second
wall, a first seam, and a second seam. The inner surface is
opposite the outer surface. The first wall extends from the outer
surface to the inner surface. The second wall is coupled to the
first wall and extends from the outer surface to the inner surface.
The first seam is formed in the inner surface. The second seam is
spaced apart from the first seam and formed in the inner surface.
The second seam forms a first non-parallel angle with the first
seam and a second non-parallel angle with the first wall.
[0008] This aspect may include one or more of the following
optional features. In some implementations, the first non-parallel
angle is equal to the second non-parallel angle. The first
non-parallel angle may be five degrees.
[0009] In some implementations, the inner surface defines a
multi-sided pyramidal shape.
[0010] In some implementations, the first seam includes a first
proximal portion and a first distal portion extending from the
first proximal portion, and wherein the first proximal portion
forms a third non-parallel angle with the first distal portion. The
second seam may include a second proximal portion and a second
distal portion extending from the second proximal portion. The
second proximal portion forms a fourth non-parallel angle with the
second distal portion. The outer surface may include a proximal
outer portion and a distal outer portion. The proximal outer
portion may extend between the first proximal portion and the
second proximal portion. The distal outer portion may extend
between the proximal outer portion, the first distal portion, and
the second distal portion. The proximal outer portion may form a
fifth non-parallel angle with the distal outer portion. The
proximal outer portion may define a pyramidal cross-sectional
shape. The distal outer portion may define a shape having a uniform
cross-sectional area.
[0011] In some implementations, the outer surface defines a
pyramidal shape.
[0012] Another aspect of the disclosure provides a leg extending
from a proximal end to a distal end. The leg may include a first
wall, a second wall, a first seam, a second seam, and an outer
surface. The first wall may extend from the proximal end to the
distal end. The second wall may be coupled to the first wall and
extend from the proximal end to the distal end. The first seam may
be spaced apart from the first wall and the second wall and extend
from the proximal end to the distal end. The second seam may be
spaced apart from the first seam, the first wall, and the second
wall and extend from the proximal end to the distal end. The outer
surface may include a first segment extending between the first
wall and the first seam, a second segment extending between the
first seam and the second seam, and a third segment extending
between the second seam and the second wall. The first segment, the
second segment, and the third segment may define a pyramidal
cross-sectional shape extending from the proximal end to the distal
end.
[0013] This aspect may include one or more of the following
optional features. In some implementations, the second seam forms a
first non-parallel angle with the first seam and a second
non-parallel angle with the first wall. The first non-parallel
angle may be equal to the second non-parallel angle. The first
non-parallel angle may be five degrees.
[0014] In some implementations, the leg includes an inner surface
opposite the outer surface and defining a multi-sided pyramidal
shape.
[0015] In some implementations, the first seam includes a first
proximal portion and a first distal portion extending from the
first proximal portion. The first proximal portion may form a first
non-parallel angle with the first distal portion. The second seam
may include a second proximal portion and a second distal portion
extending from the second proximal portion. The second proximal
portion may form a second non-parallel angle with the second distal
portion. The outer surface may include a first distal outer portion
extending from the first segment, a second distal outer portion
extending from the second segment, and a third distal outer portion
extending from the third segment. The first segment may form a
third non-parallel angle with the first distal outer portion. The
first, second, and third distal outer portions may define a shape
having a uniform cross-sectional area.
[0016] Yet another aspect of the disclosure provides a leg. The leg
may include a substrate having a first proximal segment, a second
proximal segment, and a third proximal segment. The second proximal
segment may be hingedly coupled to the first proximal segment along
a first seam. The third proximal segment may be hingedly coupled to
the second proximal segment along a second seam. The first seam may
form a first non-parallel angle with the second seam.
[0017] This aspect may include one or more of the following
optional features. In some implementations, the first proximal
segment is coupled to the third proximal segment along a third seam
forming a second non-parallel angle with the second seam. The first
non-parallel angle may be equal to the second non-parallel angle.
The first non-parallel angle may be five degrees.
[0018] In some implementations, the first proximal segment includes
a first proximal outer surface. In some implementations, the second
proximal segment includes a second proximal outer surface. In some
implementations, the third proximal segment includes a third
proximal outer surface. The first, second, and third proximal outer
surfaces may define a varying cross-sectional area. The varying
cross-sectional area may define a pyramid.
[0019] In some implementations, the leg includes a first distal
segment, a second distal segment, and a third distal segment. The
first distal segment may be hingedly coupled to the first proximal
segment and include a first distal wall and a second distal wall
parallel to the first distal wall. The second distal segment may be
hingedly coupled to the second proximal segment and include a third
distal wall and a fourth distal wall parallel to the third distal
wall. The third distal segment may be hingedly coupled to the third
proximal segment and include a fifth distal wall and a sixth distal
wall parallel to the fifth distal wall. The first distal wall may
be coupled to the sixth distal wall. The second distal wall may be
coupled to the third distal wall. The fourth distal wall may be
coupled to the fifth distal wall. The first distal segment may
include a first distal outer surface. The second distal segment may
include a second distal outer surface. The third distal segment may
include a third distal outer surface. The first, second, and third
distal outer surfaces may define a uniform cross-sectional area.
The uniform cross-sectional area may define a rectangle. In some
implementations, the leg includes a polyurethane adhesive disposed
between the first distal segment and the first proximal segment. In
some implementations, the leg includes endcap coupled to one or
more of the first distal segment, the second distal segment, or the
third distal segment, such that the endcap, the first distal
segment, the second distal segment, and the third distal segment
define an enclosed leg.
[0020] In some implementations, the substrate include a base layer
and a laminate layer. The base layer may define a channel.
[0021] In some implementations, the first proximal segment is
coupled to the third proximal segment along a third seam forming a
second non-parallel angle with the first seam.
[0022] The details of one or more implementations of the disclosure
are set forth in the accompanying drawings and the description
below. Other aspects, features, and advantages will be apparent
from the description and drawings, and from the claims.
DRAWINGS
[0023] The drawings described herein are for illustrative purposes
only of selected configurations and are not intended to limit the
scope of the present disclosure.
[0024] FIG. 1 is a perspective view of a furniture unit in
accordance with the principles of the present disclosure;
[0025] FIG. 2 is an exploded view of the furniture unit of FIG.
1;
[0026] FIG. 3 is a top view of the furniture unit of FIG. 1;
[0027] FIG. 4A is an end view of a shelf for use with the furniture
unit of FIG. 1;
[0028] FIG. 4B is an exploded view of the shelf of FIG. 4A;
[0029] FIG. 5 is an end view of a shelf for use with the furniture
unit of FIG. 1;
[0030] FIG. 6 is an end view of a shelf for use with the furniture
unit of FIG. 1;
[0031] FIG. 7A is a top view of a substrate prior to forming a
shelf for use with the furniture unit of FIG. 1;
[0032] FIG. 7B is an end view of a shelf formed with the substrate
of FIG. 7A and for use with the furniture unit of FIG. 1;
[0033] FIG. 7C is a top view of a substrate prior to forming a
ceiling baffle;
[0034] FIG. 7D is a perspective view of a ceiling baffle formed
with the substrate of FIG. 7C;
[0035] FIG. 8 is an end view of a shelf for use with the furniture
unit of FIG. 1;
[0036] FIG. 9 is an end view of a shelf for use with the furniture
unit of FIG. 1;
[0037] FIG. 10 is an end view of a bedrail in accordance with the
principles of the present disclosure;
[0038] FIG. 11 is an end view of another bedrail in accordance with
the principles of the present disclosure;
[0039] FIG. 12 is an end view of another bedrail in accordance with
the principles of the present disclosure;
[0040] FIG. 13A is a perspective view of a bedrail assembly in a
partially assembled state in accordance with the principles of the
present disclosure;
[0041] FIG. 13B is a perspective view of the bedrail assembly of
FIG. 13A in an assembled state in accordance with the principles of
the present disclosure;
[0042] FIG. 14A is cross-sectional view of a substrate during a
method of manufacturing the furniture unit of FIG. 1;
[0043] FIG. 14B is cross-sectional view of a substrate during a
method of manufacturing the furniture unit of FIG. 1;
[0044] FIG. 14C is cross-sectional view of a substrate during a
method of manufacturing the furniture unit of FIG. 1;
[0045] FIG. 14D is cross-sectional view of a substrate during a
method of manufacturing the furniture unit of FIG. 1;
[0046] FIG. 15 is a perspective view of another furniture unit in
accordance with the principles of the present disclosure;
[0047] FIG. 16 is a side view of a leg, for use with the furniture
unit of FIG. 15, in accordance with the principles of the present
disclosure;
[0048] FIG. 17 is a cross-sectional view of the leg of FIG. 16,
taken along the line 17-17;
[0049] FIG. 18 is a cross-sectional view of the leg of FIG. 16,
taken along the line 18-18;
[0050] FIG. 19 is a plan view of a substrate prior to forming the
leg of FIG. 16;
[0051] FIG. 20 is a plan view of a substrate during a method step
of forming a leg for use with the furniture unit of FIG. 15, in
accordance with the principles of the present disclosure;
[0052] FIG. 21 is a plan view of the substrate of FIG. 20 during
another method step of forming a leg for use with the furniture
unit of FIG. 15, in accordance with the principles of the present
disclosure;
[0053] FIG. 22 is a side view of the substrate of FIG. 20 during
another method step of forming a leg for use with the furniture
unit of FIG. 15, in accordance with the principles of the present
disclosure; and
[0054] FIG. 23 is a side view of another leg, for use with the
furniture unit of FIG. 15, in accordance with the principles of the
present disclosure.
[0055] Corresponding reference numerals indicate corresponding
parts throughout the drawings.
DETAILED DESCRIPTION
[0056] Example configurations will now be described more fully with
reference to the accompanying drawings. Example configurations are
provided so that this disclosure will be thorough, and will fully
convey the scope of the disclosure to those of ordinary skill in
the art. Specific details are set forth such as examples of
specific components, devices, and methods, to provide a thorough
understanding of configurations of the present disclosure. It will
be apparent to those of ordinary skill in the art that specific
details need not be employed, that example configurations may be
embodied in many different forms, and that the specific details and
the example configurations should not be construed to limit the
scope of the disclosure.
[0057] The terminology used herein is for the purpose of describing
particular exemplary configurations only and is not intended to be
limiting. As used herein, the singular articles "a," "an," and
"the" may be intended to include the plural forms as well, unless
the context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of features, steps, operations,
elements, and/or components, but do not preclude the presence or
addition of one or more other features, steps, operations,
elements, components, and/or groups thereof. The method steps,
processes, and operations described herein are not to be construed
as necessarily requiring their performance in the particular order
discussed or illustrated, unless specifically identified as an
order of performance. Additional or alternative steps may be
employed.
[0058] When an element or layer is referred to as being "on,"
"engaged to," "connected to," "attached to," or "coupled to"
another element or layer, it may be directly on, engaged,
connected, attached, or coupled to the other element or layer, or
intervening elements or layers may be present. In contrast, when an
element is referred to as being "directly on," "directly engaged
to," "directly connected to," "directly attached to," or "directly
coupled to" another element or layer, there may be no intervening
elements or layers present. Other words used to describe the
relationship between elements should be interpreted in a like
fashion (e.g., "between" versus "directly between," "adjacent"
versus "directly adjacent," etc.). As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.
[0059] The terms first, second, third, etc. may be used herein to
describe various elements, components, regions, layers and/or
sections. These elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms do not imply a
sequence or order unless clearly indicated by the context. Thus, a
first element, component, region, layer or section discussed below
could be termed a second element, component, region, layer or
section without departing from the teachings of the example
configurations.
[0060] With reference to FIGS. 1-3, a furniture unit 10 is
provided. While the furniture unit 10 is generally shown and
described herein as being a bookcase, it will be appreciated that
the furniture unit 10 (e.g., shelves, legs, backer, etc.), or parts
thereof, may include, or otherwise be utilized as, other types of
home or office furniture or fixtures (e.g., tables, bed frames,
desks, doors, ceiling panels, ceiling baffles, etc.) within the
scope of the present disclosure.
[0061] The furniture unit 10 may include one or more shelf sections
12-1, 12-2, . . . 12-n, one or more connectors 14-1, 14-2, . . .
14-n, and one or more caps 16-1, 16-2, . . . 16-n. Each shelf
section 12-1, 12-2, . . . 12-n may include a shelf 18, a lateral
leg 20, a medial leg 22, and a backer 24. The shelf 18 may extend
from a lateral end 26 to a medial end 28 opposite the lateral end
26. The lateral leg 20 may be coupled to, or otherwise supported
by, the lateral end 26 of the shelf 18. The medial leg 22 may be
coupled to, or otherwise supported by, the medial end 28 of the
shelf 18. As illustrated in FIG. 3, the backer 24 may be coupled
to, or otherwise supported by, the shelf 18, the lateral leg 20,
and/or the medial leg 22.
[0062] As illustrated in FIG. 2, the lateral and medial legs 20, 22
may each define a substantially hollow construct having upper and
lower openings 30, 32. The upper and lower openings 30, 32 may
define any of a variety of shapes. For example, while the upper and
lower openings 30, 32 are generally illustrated as defining
rectangular (e.g., square) shapes, it will be appreciated that the
upper and lower openings may define another shape such as a
triangle, a circle, or another polygon within the scope of the
present disclosure. In some implementations, the lateral and/or
medial leg 20, 22 may include the shelf 18, or a construct
substantially similar thereto. For example, the lateral leg 20 may
define another shelf, substantially similar or identical to shelf
18, supported by the lateral end 26 of the shelf 18, and the medial
leg 22 may define another shelf, substantially similar or identical
to shelf 18, supported by the medial end 28 of the shelf 18.
[0063] With further reference to FIG. 2, the connectors 14-1, 14-2,
. . . 14-n may each include a first coupling portion 34, a second
coupling portion 36, and a stop portion 38. The first and second
coupling portions 34, 36 may define any of a variety of shapes. For
example, while the first and second coupling portions 34, 36 are
generally illustrated as defining rectangular (e.g., square)
shapes, it will be appreciated that the first and second coupling
portions 34, 36 may each define another shape such as a triangle, a
circle, or another polygon within the scope of the present
disclosure. In this regard, the size and shape of the first and
second coupling portions 34, 36 may correspond to the size and
shape of one or both of the upper or lower openings 30, 32 of the
lateral and medial legs 20, 22, such that the upper or lower
openings 30, 32 can receive the first or second coupling portions
34, 36 of the connectors 14-1, 14-2, . . . 14-n in an assembled
configuration, as described in more detail below.
[0064] The stop portion 38 may extend outwardly from, or otherwise
relative to, the first or second coupling portions 34, 36 of the
connectors 14-1, 14-2, . . . 14-n. In some implementations, the
stop portion 38 defines an outwardly extending flange relative to
the first and second coupling portions 34, 36. In this regard, the
stop portion 38 may define a shape that is substantially similar to
the shape defined by the first or second coupling portions 34,
36.
[0065] The caps 16-1, 16-2, . . . 16-n may each include a coupling
portion 40 and a stop portion 42. The coupling portion 40 may
define any of a variety of shapes. For example, while the coupling
portion 40 is generally illustrated as defining a rectangular
(e.g., square) shape, it will be appreciated that the coupling
portion 40 may define another shape such as a triangle, a circle,
or another polygon within the scope of the present disclosure. In
this regard, the size and shape of the coupling portion 40 may
correspond to the size and shape of one or both of the upper or
lower openings 30, 32 of the lateral and medial legs 20, 22, such
that the upper or lower openings 30, 32 can receive the coupling
portion 40 of the caps 16-1, 16-2, . . . 16-n in an assembled
configuration, as described in more detail below. The stop portion
42 may extend outwardly from, or otherwise relative to, the
coupling portion 40 of the caps 16-1, 16-2, . . . 16-n. In some
implementations, the stop portion 42 defines an outwardly extending
flange at, and relative to, an uppermost portion of the coupling
portion 40. In this regard, the stop portion 42 may define a shape
that is substantially similar to the shape defined by the coupling
portion 42.
[0066] As illustrated in FIGS. 1 and 2, in the assembled
configuration, the shelf sections 12-1, 12-2, . . . 12-n may be
arranged in a stacked configuration. In this regard, the lateral
leg 20 of the first shelf section 12-1 may be removably coupled to
the lateral leg 20 of the second shelf section 12-2, and the medial
leg 22 of the first shelf section 12-1 may be removably coupled to
the medial leg 22 of the second shelf section 12-2. For example,
one or more connectors 14-1, 14-2, . . . 14-n may be removably
coupled to the lateral leg 20 of the first shelf section 12-1 and
to the lateral leg 20 of the second shelf section 12-1, and another
one or more connectors 14-1, 14-2, . . . 14-n may be removably
coupled to the medial leg 22 of the first shelf section 12-1 and to
the medial leg 22 of the second shelf section 12-1. In particular,
the first coupling portion 34 of one or more of the connectors
14-1, 14-2, . . . 14-n may be disposed within one or more of the
upper openings 30 of the lateral leg 20 of the first shelf section
12-1, and the second coupling portion 36 may be disposed within one
or more of the lower openings 32 of the lateral leg 20 of the
second shelf section 12-2, such that the stop portion 38 engages
the lateral legs 20 of the first and second shelf sections 12-1,
12-2. Similarly, the first coupling portion 34 of one or more of
the connectors 14-1, 14-2, . . . 14-n may be disposed within one or
more of the upper openings 30 of the medial leg 22 of the first
shelf section 12-1, and the second coupling portion 36 may be
disposed within one or more of the lower openings 32 of the medial
leg 22 of the second shelf section 12-2, such that the stop portion
38 engages the medial legs 22 of the first and second shelf
sections 12-1, 12-2.
[0067] With reference to FIGS. 4A and 4B, the shelf 18 may include,
or otherwise be formed from, a substrate 46 having a layered
construct. In this regard, the substrate 46 may include a base
layer 48, an upper laminate layer 50, and a lower laminate layer
52. The base layer 48 and the upper and lower laminate layers 50,
52 may each be formed from one or more of a variety of materials.
In some implementations, the base layer 48 is formed from a
medium-density fiberboard material, a polymer material (e.g.,
polyvinyl chloride), or a particle board material, and the laminate
layers 50, 52 are formed from a paper material or a polymer
material (e.g., polypropylene).
[0068] The base layer 48 may include an upper surface 54, a lower
surface 56 opposite the upper surface 54, and a peripheral surface
58. The upper and lower surfaces 54, 56 may extend from a proximal
portion 60 of the substrate 46 to a distal portion 62 of the
substrate 46. The peripheral surface 58 may extend from the upper
surface 54 to the lower surface 56. In this regard, the peripheral
surface 58 may include a proximal peripheral surface 64, a distal
peripheral surface 66, a lateral peripheral surface 68, and a
medial peripheral surface 70. The proximal peripheral surface 64
may be disposed in the proximal portion 60 of the substrate 46. The
distal peripheral surface 66 may be disposed in the distal portion
62 of the substrate 46 opposite the proximal peripheral surface 64.
The lateral peripheral surface 68 may extend from the proximal
peripheral surface 64 to the distal peripheral surface 66. The
medial peripheral surface 70 may extend from the proximal
peripheral surface 64 to the distal peripheral surface 66 opposite
the lateral peripheral surface 68.
[0069] The upper laminate layer 50 may include an upper surface 74,
a lower surface 76 opposite the upper surface 74, and a peripheral
surface 78. The upper and lower surfaces 74, 76 may extend from the
proximal portion 60 of the substrate 46 to the distal portion 62 of
the substrate 46. The peripheral surface 78 may extend from the
upper surface 74 to the lower surface 76. In this regard, the
peripheral surface 78 may include a proximal peripheral surface 80,
a distal peripheral surface 82, a lateral peripheral surface 84,
and a medial peripheral surface 86. The proximal peripheral surface
80 may be disposed in the proximal portion 60 of the substrate 46.
The distal peripheral surface 82 may be disposed in the distal
portion 62 of the substrate 46 opposite the proximal peripheral
surface 80. The lateral peripheral surface 84 may extend from the
proximal peripheral surface 80 to the distal peripheral surface 82.
The medial peripheral surface 86 may extend from the proximal
peripheral surface 80 to the distal peripheral surface 82 opposite
the lateral peripheral surface 84.
[0070] The lower laminate layer 52 may include an upper surface 88,
a lower surface 90 opposite the upper surface 88, and a peripheral
surface 92. The upper and lower surfaces 88, 90 may extend from the
proximal portion 60 of the substrate 46 to the distal portion 62 of
the substrate 46. The peripheral surface 92 may extend from the
upper surface 88 to the lower surface 90. In this regard, the
peripheral surface 92 may include a proximal peripheral surface 94,
a distal peripheral surface 96, a lateral peripheral surface 98,
and a medial peripheral surface 100. The proximal peripheral
surface 94 may be disposed in the proximal portion 60 of the
substrate 46. The distal peripheral surface 96 may be disposed in
the distal portion 62 of the substrate 46 opposite the proximal
peripheral surface 94. The lateral peripheral surface 98 may extend
from the proximal peripheral surface 94 to the distal peripheral
surface 96. The medial peripheral surface 100 may extend from the
proximal peripheral surface 94 to the distal peripheral surface 96
opposite the lateral peripheral surface 98.
[0071] In the assembled configuration, the upper surface 54 of the
base layer 48 may engage the lower surface 76 of the upper laminate
layer 50, and the lower surface 56 of the base layer 48 may engage
the upper surface 88 of the lower laminate layer 52, such that the
upper surface 74 of the upper laminate layer 50, the lower surface
90 of the lower laminate layer 52, the peripheral surface 58 of
base layer 48, the peripheral surface 78 upper laminate layer 50,
and the peripheral surface 92 of lower laminate layer 52 define
outermost surfaces of the substrate 46. In some implementations,
the upper surface 54 of the base layer 48 may be bonded to the
lower surface 76 of the upper laminate layer 50 using an adhesive
or other suitable technique, and the lower surface 56 of the base
layer 48 may be bonded to the upper surface 88 of the lower
laminate layer 52 using an adhesive or other suitable technique.
While the substrate 46 is generally shown and described herein as
including the base layer 48, the upper laminate layer 50, and the
lower laminate layer 52, the substrate 46 may include the base
layer 48 and one of the upper and lower laminate layers 50, 52
within the scope of the present disclosure. In this regard, in some
implementations, the upper surface 54 or the lower surface 56 of
the base layer 48 may define an outermost surface of the substrate
46.
[0072] As illustrated in FIG. 4A, the shelf 18 may include, or
otherwise define, a first seam 104-1, a second seam 104-2 spaced
apart from the first seam 104-1, and a third seam 104-3 spaced
apart from the first and second seams 104-1, 104-2. It will be
appreciated that the shelf 18 may include more or less than three
seams within the scope of the present disclosure. For example, as
illustrated in FIG. 4A, in some implementations, the shelf 18 may
include first, second and third seams 104-1, 104-2, 104-3 in the
proximal portion 60 of the substrate 46, and fourth, fifth, and
sixth seams 104-4, 104-5, 104-6 in the distal portion 62 of the
substrate 46. The seams 104-1, 104-2, 104-3 may extend through the
base layer 48. Where the substrate 46 includes the base layer 48
and both of the upper and lower laminate layers 50, 52, the seams
104-1, 104-2, 104-3 may extend through the base layer 48 and
through one of the upper and lower laminate layers 50, 52. Where
the substrate 46 includes the base layer 48 and one of the upper
and lower laminate layers 50, 52, the seams 104-1, 104-2, 104-3 may
extend through only the base layer 48. The seams 104-1, 104-2, . .
. 104-n may extend from the lateral peripheral surfaces 68, 84, 98
to the medial peripheral surfaces 70, 86, 100. In this regard, the
seams 104-1, 104-2, 104-3 may extend in a direction substantially
parallel (+/-5 degrees) to the proximal peripheral surfaces 64, 80,
94 or the distal peripheral surfaces 66, 82, 96.
[0073] With continued reference to FIGS. 4A and 4B, the shelf 18
may further include, or otherwise define, a first fold 106-1, a
second fold 106-2 spaced apart from the first fold 106-1, and a
third fold 106-3 spaced apart from the first and second folds
106-1, 106-2. It will be appreciated that the shelf 18 may include
more or less than three folds within the scope of the present
disclosure. In this regard, the number "n" of folds 106-1, 106-2, .
. . 106-n may equal the number of seams 104-1, 104-2, . . . 104-n.
Where the substrate 46 includes the base layer 48 and both of the
upper and lower laminate layers 50, 52, the folds 106-1, 106-2,
106-3 may be formed in the one of the upper and lower laminate
layers 50, 52 which does not include the seams 104-1, 104-2, 104-3.
Where the substrate 46 includes the base layer 48 and one of the
upper and lower laminate layers 50, 52, the folds 106-1, 106-2,
106-3 may be formed in that one of the upper and lower laminate
layers 50, 52. The folds 106-1, 106-2, 106-3 may extend from the
lateral peripheral surfaces 68, 84, 98 to the medial peripheral
surfaces 70, 86, 100. In some implementations, the folds 106-1,
106-2, 106-3 extend in a direction substantially parallel (+/-5
degrees) to the proximal peripheral surfaces 64, 80, 94 or the
distal peripheral surfaces 66, 82, 96. In this regard, each fold
106-1, 106-2, . . . 106-n may be aligned with one of the seams
104-1, 104-2, . . . 104-n.
[0074] With reference to FIGS. 4 and 14A-14D, a method of
manufacturing any component of shelf section 12-1, 12-2, . . . 12-n
(i.e, shelf 18, lateral leg 20, medial leg 22, and backer 24) of
the furniture unit 10 will now be described. The component of shelf
section 12-1, 12-2, . . . 12-n may be manufactured from the
substrate 46 having a thickness T extending between an upper
surface (e.g., upper surface 74) and a lower surface (e.g., lower
surface 90). The thickness T may be between two millimeters and ten
millimeters. In some implementations, the thickness T may be
substantially equal to five millimeters.
[0075] With particular reference to FIG. 14A, the method may
include providing a tool 200 (e.g., a router, a blade, a bit, etc.)
and using the tool to form a plurality of primary channels 202 in
the substrate 46, e.g, by miter cutting the plurality of primary
channels 202 in the substrate 46. In this regard, the number and
location of the primary channels 202 may correspond to the number
and location of the seams 104-1, 104-2, . . . 104-n or the number
and location of the folds 106-1, 106-2, . . . 106-n. The tool 200
may include a male portion 203 and a female portion 205 opposite
the male portion 203. As illustrated, in some configurations, the
male portion 203 defines a convex profile and the female portion
205 defines a concave profile. It will be appreciated, however,
that the male and female portions 203, 205 may define other
profiles (e.g., triangular, rectangular, etc.) within the scope of
the present disclosure. In this regard, the size and shape of the
male portion 203 may correspond to, or otherwise be the same as,
the size and shape of the female portion 205. Accordingly, as
illustrated in FIG. 14A, the primary channels 202 may be defined by
a first channel wall 204 having a male portion 207 formed by the
female portion 205 of the tool 200, and a second channel wall 206
having a female portion 209 formed by the male portion 203 of the
tool 200.
[0076] The first and second channel walls 204, 206 may extend
through a majority of the thickness T of the substrate 46. For
example, the first and second channel walls 204, 206 may extend
through between approximately seventy percent of the thickness T of
the substrate 46 and ninety-nine percent of the thickness T of the
substrate 46. In some implementations, the first and second channel
walls 204, 206 may extend through an entirety of the base layer 48
and through an entirety of the lower laminate layer 52. In this
regard, the first and second channels walls 204, 206 may define a
common edge 208 adjacent the lower surface 76 of upper laminate
layer 50, and have an angle .alpha. therebetween. The angle .alpha.
may be between about fifteen degrees and about one hundred
sixty-five degrees. As illustrated in FIG. 14A, in some
implementations, the angle .alpha. is substantially equal to ninety
degrees.
[0077] With continued reference to FIG. 14A, the method may further
include providing a tool 210 and forming one or more secondary
channels 212 in the substrate 46. As illustrated in FIG. 14A, the
secondary channels 212 may extend through the lower laminate layer
52 to expose the lower surface 56 of the base layer 48. In this
regard, forming the secondary channels 212 may include removing a
portion of the lower laminate layer 52. The secondary channels 212
may extend from the lateral peripheral surfaces 68, 84, 98 to the
medial peripheral surfaces 70, 86, 100.
[0078] With reference to FIG. 14B, the method may also include
folding the substrate 46 such that each first channel wall 204 of
primary channel 202 engages the second channel wall 206 of the same
of primary channel 202 to define a corresponding seam 104-n and
fold 106-n. In this regard, the female portion 209 of each primary
channel 202 may receive the male portion 207 of such primary
channel 202. For example, the method may include performing a
plurality of folding operations to define the plurality of seams
104-1, 104-2, . . . 104-n and the plurality of folds 106-1, 106-2,
. . . 106-n. In this regard, each fold 106-1, 106-2, . . . 106-n
may define, or otherwise act as, a hinge for folding the substrate
46. Accordingly each fold 106-1, 106-2, . . . 106-n may be referred
to herein as a hinge 106-1, 106-2, . . . 106-n. As illustrated in
FIGS. 4A and 4B, in some implementations, the folding operations,
and the plurality of seams 104-1, 104-2, . . . 104-n and the
plurality of folds 106-1, 106-2, . . . 106-n defined thereby, forms
a hollow proximal support 214 at the proximal portion 60 of the
substrate 46 and a hollow distal support 216 at the distal portion
62 of the substrate 46. The hollow proximal support 214 and/or the
hollow distal support 216 may define a polygonal cross section
extending from the lateral peripheral surfaces 68, 84, 98 to the
medial peripheral surfaces 70, 86, 100. For example, the hollow
proximal support 214 and the hollow distal support 216 may define a
rectangular (e.g., square) cross section extending from the lateral
peripheral surfaces 68, 84, 98 to the medial peripheral surfaces
70, 86, 100. In this regard, the upper surface 74 of the upper
laminate layer 50 may include a first portion 218 and a second
portion 219. The first portion 218 may extend from the proximal
peripheral surface 80 to a first seam 104-1, and the second portion
219 may extend from the first seam 104-1 to a second seam 104-2.
The first portion 218 and the second portion 219 may define an
angle .theta. therebetween. The angle .theta. may be between about
fifteen degrees and about one hundred sixty-five degrees. As
illustrated in FIGS. 4 and 14B, in some implementations, the angle
.theta. is substantially equal to ninety degrees.
[0079] With reference to FIG. 14C, folding the substrate 46 may
also include engaging the proximal peripheral surfaces 64, 80, or
94 or the distal peripheral surfaces 66, 82, or 96 with the upper
surface 54 of the base layer 48 or with the lower surface 56 of the
base layer 48. In particular, folding the substrate 46 may include
positioning the proximal peripheral surfaces 64, 80, 94 or the
distal peripheral surfaces 66, 82, 96 within one of the secondary
channels 212 such that the proximal peripheral surfaces 64, 80, 94
or the distal peripheral surfaces 66, 82, 96 engage the upper
surface 54 or the lower surface 56 of the base layer 48. In this
regard, the proximal peripheral surfaces 64, 80, 94 or the distal
peripheral surfaces 66, 82, 96 may define an angle .beta. relative
to one or more of the upper surfaces 54, 74, 88 or the lower
surfaces 56, 76, 90. For example, the proximal peripheral surfaces
64, 80, 94 or the distal peripheral surfaces 66, 82, 96 may define
an angle .beta. relative to the lower surface 90. The angle .beta.
may be between about ninety degrees and about one hundred eighty
degrees. For example, if the hollow support portion 214 defines a
rectangle the angle .beta. may be substantially equal to ninety
degrees. If the hollow support portion 214 defines a triangle the
angle .beta. may be greater than ninety degrees. In some
implementations, if the hollow support portion 214 defines a
triangle, the angle .beta. may be substantially equal to one
hundred twenty degrees.
[0080] In some implementations, engaging the proximal peripheral
surfaces 64, 80, or 94 or the distal peripheral surfaces 66, 82, or
96 with the upper surface 54 of the base layer 48 or with the lower
surface 56 of the base layer 48 may also include coupling the
proximal peripheral surfaces 64, 80, or 94 or the distal peripheral
surfaces 66, 82, or 96 with the upper surface 54 of the base layer
48 or with the lower surface 56 of the base layer 48 using an
adhesive or other suitable technique.
[0081] As illustrated in FIGS. 4A and 4B, in some implementations,
folding the substrate 46 to form the hollow proximal support 214
and/or the hollow distal support 216 includes folding the proximal
portion 60 in a counterclockwise direction and folding the distal
portion 62 in a clockwise direction.
[0082] With continued reference to FIG. 14C, the method may also
include forming one or more apertures 220 through the substrate 46
and placing a primary connector 222 in each of the one or more
apertures 220. For example, the method may include forming the one
or more apertures 220 through the hollow proximal support 214 or
the hollow distal support 216. The primary connector 222 may
include a cross-dowel having an aperture 224 formed therein.
[0083] With reference to FIG. 14D, the method may further include
coupling the shelf 18 to the lateral leg 20 or the medial leg 22.
In some implementations, the method may include coupling a
secondary connector 226 to each of the primary connectors 222 to
couple the shelf 18 to the lateral leg 20 and the medial leg 22.
For example, the method may include extending the secondary
connectors 226 through the lateral leg 20 or the medial leg 22 and
into the aperture 224 of the primary connector 222. In some
implementations, extending the secondary connector 226 into the
aperture 224 of the primary connector 222 includes threadably
engaging the secondary connector 226 with the primary connector 222
within the aperture 224.
[0084] With reference to FIG. 5, another shelf 18a for use with the
furniture unit 10 is shown. The structure, function, and method of
manufacturing the shelf 18a may be substantially similar to that of
the shelf 18, apart from any exceptions described below and/or
shown in the Figures. Accordingly, the structure and/or function of
similar features will not be described again in detail. In
addition, like reference numerals are used hereinafter and in the
drawings to identify like features, while like reference numerals
containing letter extensions (i.e., "a") are used to identify those
features that have been modified.
[0085] The shelf 18a may include the hollow proximal support 214
and a hollow distal support 216a. As illustrated in FIG. 5, the
hollow proximal support 214 and the hollow distal support 216a may
be disposed on opposite sides of the shelf 18a. In this regard,
folding the substrate 46 to form the hollow proximal support 214
may include folding the proximal portion 60 in a counterclockwise
direction, and folding the substrate 46 to form the hollow distal
support 216a may include folding the distal portion 62 in a
counterclockwise direction.
[0086] With reference to FIG. 6, another shelf 18b for use with the
furniture unit 10 is shown. The structure, function, and method of
manufacturing the shelf 18b may be substantially similar to that of
the shelf 18, apart from any exceptions described below and/or
shown in the Figures. Accordingly, the structure and/or function of
similar features will not be described again in detail. In
addition, like reference numerals are used hereinafter and in the
drawings to identify like features, while like reference numerals
containing letter extensions (i.e., "b") are used to identify those
features that have been modified.
[0087] The shelf 18b may include a hollow support 216b extending
from the proximal portion 60 to the distal portion 62 of the
substrate 46. In this regard, folding the substrate 46 to form the
hollow support 216b may include folding the proximal portion 60 in
a counterclockwise direction, or folding the distal portion 62 in a
clockwise direction, such that the proximal peripheral surfaces 64,
80, or 94 are disposed adjacent the distal peripheral surfaces 66,
82, or 96.
[0088] With reference to FIGS. 7A and 7B, another shelf 18c (FIG.
7A) formed from the substrate 46, and for use with the assembly 10,
is shown. The structure, function, and method of manufacturing the
shelf 18c may be substantially similar to that of the shelf 18b,
apart from any exceptions described below and/or shown in the
Figures. Accordingly, the structure and/or function of similar
features will not be described again in detail. In addition, like
reference numerals are used hereinafter and in the drawings to
identify like features, while like reference numerals containing
letter extensions (i.e., "c") are used to identify those features
that have been modified.
[0089] The substrate 46 of the shelf 18c may include the hollow
support 216b extending from the proximal portion 60 to the distal
portion 62 of the substrate 46, and one or more covers 227. The
cover 227 may engage a portion 228 of the lateral peripheral
surfaces 68, 84, or 98 or a portion 228 of the medial peripheral
surfaces 70, 86, or 100. As illustrated in FIG. 7B, in some
implementations, the shelf 18c may have two covers 227; one cover
227 may engage a portion 228 of the lateral peripheral surfaces 68,
84, or 98 and the other cover 227 may engage a portion 228 of the
medial peripheral surfaces 70, 86, or 100. In this regard, in these
implementations, the shelf 18c may have the appearance of a solid
piece (e.g., a solid piece of wood) without any openings. The
substrate 46 may further include a fold 230 that may be formed in
one of the upper and lower laminate layers 50, 52 such that one of
the upper surfaces 54, 74, 88 or one of the lower surfaces 56, 76,
90 engages the portion 228 of the lateral peripheral surfaces 68,
84, or 98 or the medial peripheral surfaces 70, 86, or 100. In some
implementations, the shelf 18c may be utilized as a ceiling panel
or baffle.
[0090] In other implementations, the shelf 18c may be formed
without one or both of the covers 227, or without one or more of
the seams 104-1, 104-2, . . . 104-n, such that the shelf 18c
defines a four-sided construct or a five-sided construct in which
each side defines a ninety degree angle relative to any adjacent
sides. For example, with reference to FIGS. 7C and 7D, a five-sided
ceiling baffle 18c' (FIG. 7D), formed from the substrate 46, is
shown. The structure, function, and method of manufacturing the
ceiling baffle 18c' may be substantially similar to that of the
shelf 18c, apart from any exceptions described below and/or shown
in the Figures. In this regard, the substrate 46 may define a
ceiling baffle 18c' having an opening 229 into the hollow support
216c'.
[0091] With reference to FIG. 8, another shelf 18d for use with the
furniture unit 10 is shown. The structure, function, and method of
manufacturing the shelf 18d may be substantially similar to that of
the shelf 18, apart from any exceptions described below and/or
shown in the Figures. Accordingly, the structure and/or function of
similar features will not be described again in detail. In
addition, like reference numerals are used hereinafter and in the
drawings to identify like features, while like reference numerals
containing letter extensions (i.e., "d") are used to identify those
features that have been modified.
[0092] The shelf 18d may include a support 216d defining a
corrugated construct extending from the proximal portion 60 to the
distal portion 62 of the substrate 46. In this regard, folding the
substrate 46 to form the support 216d may include folding one or
more portions of the substrate in a clockwise direction and a
counterclockwise direction, such that one of the upper surfaces 54,
74, 88 or one of the lower surfaces 56, 76, 90 engages another one
of the upper surfaces 54, 74, 88 or one of the lower surfaces 56,
76, 90. As illustrated in FIG. 8, folding the substrate 46 may
include directly engaging various portions of the lower surface 56
of the base layer 48 with various other portions of the lower
surface 56 of the base layer 48. In other implementations, folding
the substrate 46 may include directly engaging various portions of
the upper surface 54 of the base layer 48 with various other
portions of the upper surface 54 of the base layer 48
[0093] With reference to FIG. 9, another shelf 18e for use with the
furniture unit 10 is shown. The structure, function, and method of
manufacturing the shelf 18e may be substantially similar to that of
the shelves 18 and 18b, apart from any exceptions described below
and/or shown in the Figures. Accordingly, the structure and/or
function of similar features will not be described again in detail.
In addition, like reference numerals are used hereinafter and in
the drawings to identify like features, while like reference
numerals containing letter extensions (i.e., "e") are used to
identify those features that have been modified. While article 18e
is generally shown and described herein as being a "shelf 18e," it
will be appreciated that article 18e may be utilized in various
ways within the scope of the present disclosure. For example, shelf
18e may be utilized as a "shelf" for a bed. In this regard, the
shelf 18e may be utilized, and referred to herein, as a
bedrail.
[0094] The shelf 18e is a variation of the shelves 18 and 18b shown
in FIGS. 4 and 6, including a hollow proximal support 214e and the
hollow distal support 216b, and excluding lower laminate layer 52.
In particular, the shelf 18e may include the hollow support 216b
extending from the proximal portion 60 to the distal portion 62 of
the substrate 46. Folding the substrate 46 may include forming the
hollow proximal support 214e by folding the proximal portion 60 in
a counterclockwise direction, and forming the hollow distal support
216b by folding the substrate 46 in a clockwise direction from the
proximal portion 60 to the distal portion 62 such that the proximal
peripheral surfaces 64, 80 are disposed adjacent the distal
peripheral surfaces 66, 82. In some implementations, the proximal
peripheral surfaces 64, 80 and the distal peripheral surfaces 66,
82 engage the lower surface 56 of the base layer 48. In this
regard, the upper surface 74 of the upper laminate layer 50 may
include a first portion 232 (e.g., a forward portion) extending
from a first seam 104-1 to the proximal peripheral surfaces 64, 80,
and a second portion 234 (e.g., a rearward portion) extending from
a second seam 104-2 to the distal peripheral surfaces 66, 82. The
first portion 232 of the upper surface 74 may engage the second
portion 234 of the upper surface 74. In some implementations, the
first portion 232 of the upper surface 74 is attached to the second
portion 234 of the upper surface 74. For example, the the first
portion 232 of the upper surface 74 may be coupled to the second
portion 234 of the upper surface 74 with an adhesive or other
suitable fastening technique. The substrate 46 of shelf 18e also
may include lower laminate layer 52 such that the proximal
peripheral surfaces 64, 80, or 94 are disposed adjacent the distal
peripheral surfaces 66, 82, or 96; and in some implementations, the
proximal peripheral surfaces 64, 80, or 94 and the distal
peripheral surfaces 66, 82, or 96 engage the lower surface 90 of
the lower laminate layer 52. In some implementations, the proximal
peripheral surfaces 64, 80, or 94 and the distal peripheral
surfaces 66, 82, or 96 are attached to the lower surface 90 of the
lower laminate layer 52.
[0095] With reference to FIG. 10, a bedrail 18f is shown. The
structure, function, and method of manufacturing the bedrail 18f
may be substantially similar to that of the shelves 18, 18b, 18e,
etc. apart from any exceptions described below and/or shown in the
Figures. Accordingly, the structure and/or function of similar
features will not be described again in detail. In addition, like
reference numerals are used hereinafter and in the drawings to
identify like features, while like reference numerals containing
letter extensions (i.e., "f") are used to identify those features
that have been modified. While article 18f is generally shown and
described herein as being a "bedrail 18f," it will be appreciated
that article 18f may be utilized in various ways within the scope
of the present disclosure. For example, the bedrail 18f may be
utilized as a "shelf" for use with the furniture unit 10.
[0096] The bedrail 18f is a variation of the shelf 18e shown in
FIG. 9, including a hollow proximal support 214f and a hollow
distal support 216f. In some implementations, the bedrail 18f, like
the shelf 18e, excludes the lower laminate layer 52. In other
implementations, the bedrail 18f, like the shelf 18, includes the
lower laminate layer 52. In particular, the bedrail 18f may include
the hollow support 216f extending from the proximal portion 60 to
the distal portion 62 of the substrate 46.
[0097] Folding the substrate 46 may include forming the hollow
proximal support 214f by folding the proximal portion 60 in a
counterclockwise direction, and forming the hollow distal support
216f by folding the substrate 46 in a clockwise direction from the
proximal portion 60 to the distal portion 62 such that the proximal
peripheral surfaces 64, 80 face a first direction and the distal
peripheral surfaces 66, 82 face a second direction opposite (e.g.,
approximately 180 degrees offset) the first direction. The first
portion 232 may extend from the first seam 104-1 to a third seam
104-3f and from the third seam 104-3f to the proximal peripheral
surfaces 64, 80, and the second portion 234 may extend from the
second seam 104-2 to a fourth seam 104-4f and from the fourth seam
104-4f to the distal peripheral surfaces 66, 82. In particular, the
first portion 232 may extend in the first direction from the third
seam 104-3f to the proximal peripheral surfaces 64, 80, and the
second portion 234 may extend in the opposite second direction from
the fourth seam 104-4f to the distal peripheral surfaces 66,
82.
[0098] A portion of the upper surface 74 of the upper laminate
layer 50, as well as the proximal peripheral surfaces 64, 80 and
the distal peripheral surfaces 66, 82, may engage the lower surface
56 of the base layer 48, while the first portion 232 of the upper
surface 74 may engage the second portion 234 of the upper surface
74. In some implementations, the first portion 232 of the upper
surface 74 is attached to the second portion 234 of the upper
surface 74. For example, the first portion 232 of the upper surface
74 may be coupled to the second portion 234 of the upper surface 74
with an adhesive or other suitable fastening technique.
[0099] As previously described, the substrate 46 of the bedrail 18f
also may include lower laminate layer 52 (not shown) such that the
proximal peripheral surfaces 64, 80, or 94 face in a direction
opposite the distal peripheral surfaces 66, 82, or 96; and in some
implementations, the proximal peripheral surfaces 64, 80, or 94 and
the distal peripheral surfaces 66, 82, or 96 engage the lower
surface 90 of the lower laminate layer 52.
[0100] With reference to FIG. 11, a bedrail 18g is shown. The
structure, function, and method of manufacturing the bedrail 18g
may be substantially similar to that of the bedrail 18f apart from
any exceptions described below and/or shown in the Figures.
Accordingly, the structure and/or function of similar features will
not be described again in detail. In addition, like reference
numerals are used hereinafter and in the drawings to identify like
features, while like reference numerals containing letter
extensions (i.e., "g") are used to identify those features that
have been modified. While article 18g is generally shown and
described herein as being a "bedrail 18g," it will be appreciated
that article 18g may be utilized in various ways within the scope
of the present disclosure. For example, the bedrail 18g may be
utilized as a "shelf" for use with the furniture unit 10.
[0101] The bedrail 18g is a variation of the bedrail 18f shown in
FIG. 10, including the hollow distal support 216f. In some
implementations, the bedrail 18g, like the bedrail 18f, excludes
the lower laminate layer 52. In other implementations, the bedrail
18g, like the bedrail 18f, includes the lower laminate layer 52. In
particular, the bedrail 18g may include the hollow support 216f
extending from the proximal portion 60 to the distal portion 62 of
the substrate 46. Folding the substrate 46 may include forming the
hollow distal support 216f by folding the substrate 46 in a
clockwise direction from the proximal portion 60 to the distal
portion 62 such that the proximal peripheral surfaces 64, 80 face a
first direction and the distal peripheral surfaces 66, 82 face a
second direction opposite (e.g., approximately 180 degrees offset)
the first direction. In this regard, the distal peripheral surfaces
66, 82 and a portion of the upper surface 74 of the upper laminate
layer 50 may engage the lower surface 56 of the base layer 48,
while the second portion 234 of the upper surface 74 may be
exposed. In some implementations, the upper surface 74 of the upper
laminate layer 50 is attached to the lower surface 56 of the base
layer 48. For example, the upper surface 74 of the upper laminate
layer 50 may be coupled to the lower surface 56 of the base layer
48 with an adhesive or other suitable fastening technique. In some
implementations, the proximal peripheral surfaces 64, 80 are
aligned (e.g., flush or coplanar) with the second portion 234 of
the upper surface 74.
[0102] As previously described, the substrate 46 of the bedrail 18g
also may include lower laminate layer 52 (not shown) such that the
proximal peripheral surfaces 64, 80, or 94 face in a direction
opposite the distal peripheral surfaces 66, 82, or 96; and in some
implementations, the distal peripheral surfaces 66, 82, or 96
engage the lower surface 90 of the lower laminate layer 52.
[0103] With reference to FIG. 12, a bedrail 18h is shown. The
structure, function, and method of manufacturing the bedrail 18h
may be substantially similar to that of the bedrail 18f apart from
any exceptions described below and/or shown in the Figures.
Accordingly, the structure and/or function of similar features will
not be described again in detail. In addition, like reference
numerals are used hereinafter and in the drawings to identify like
features, while like reference numerals containing letter
extensions (i.e., "h") are used to identify those features that
have been modified. While article 18h is generally shown and
described herein as being a "bedrail 18h" it will be appreciated
that article 18h may be utilized in various ways within the scope
of the present disclosure. For example, the bedrail 18h may be
utilized as a "shelf" for use with the furniture unit 10.
[0104] The bedrail 18h is a variation of the bedrail 18f shown in
FIG. 10, including the hollow proximal support 214f and a hollow
distal support 216h. In some implementations, the bedrail 18h, like
the bedrail 18f, excludes the lower laminate layer 52. In other
implementations, the bedrail 18h, like the bedrail 18f, includes
the lower laminate layer 52. In particular, the bedrail 18f may
include the hollow support 216h extending from the proximal portion
60 to the distal portion 62 of the substrate 46. Folding the
substrate 46 may include forming the hollow distal support 216h by
folding the substrate 46 in a clockwise direction from the proximal
portion 60 to the distal portion 62 such that the proximal
peripheral surfaces 64, 80 face in a direction opposite (e.g.,
approximately 180 degrees offset) the distal peripheral surfaces
66, 82. The first portion 232 may extend from the first seam 104-1
to the proximal peripheral surfaces 64, 80, and the second portion
234 may extend from the second seam 104-2 to the distal peripheral
surfaces 66, 82. A portion of the upper surface 74 of the upper
laminate layer 50, as well as the proximal peripheral surfaces 64,
80 and the distal peripheral surfaces 66, 82, may engage the lower
surface 56 of the base layer 48, while the first portion 232 of the
upper surface 74 may engage the second portion 234 of the upper
surface 74.
[0105] In some implementations, the bedrail 18h includes a
plurality of seams 104-3h, 104-4h, . . . 104-nh disposed between
the second seam 104-2 and the proximal portion 60 of the substrate
46. As illustrated in FIG. 12, in some implementations, the bedrail
18h may include three seams 104-nh. It will be appreciated,
however, that the bedrail 18h may include more or less than three
seams 104-nh within the scope of the present disclosure. In forming
the hollow distal support 216h by folding the substrate 46 in a
clockwise direction, as previously described, from the proximal
portion 60 to the distal portion 62, a portion of the upper surface
74 of the upper laminate layer 50, and a portion of the lower
surface 56 of the substrate 46, may define a multi-sided shape. In
this regard, a portion of the upper surface 74 and a portion of the
lower surface 56 may each define a portion of a polygon. For
example, a portion of the upper surface 74 and a portion of the
lower surface 56 may each define a plurality (e.g., three) of sides
of a polygon. For example, as illustrated in FIG. 12, a portion of
the upper surface 74 and a portion of the lower surface 56 may
define a plurality of sides of a hexagon, an octagon, a decagon, or
other similar polygon extending between the second seam 104-2 and
another of the seams 104-3n. In this regard, if the portion of the
upper surface 74 and the portion of the lower surface 56 define a
plurality of sides of an octagon, the angle defined by adjacent
seams of the plurality of seams 104-3h, 104-4h, . . . 104-nh may be
substantially equal to ninety degrees. The portion of the upper
surface 74 may be substantially parallel to the portion of the
lower surface 56. In this regard, depending on the number of seams
104-3n, the portion of the upper surface 74 and the portion of the
lower surface 56 may define, or otherwise resemble, a segmented
arcuate shape (e.g., semi-cylindrical).
[0106] With reference to FIGS. 13A and 13B, a bedrail assembly 300
is shown. While article 300 is generally shown and described herein
as being a "bedrail assembly 300," it will be appreciated that
article 300 may be utilized in various ways within the scope of the
present disclosure. For example, the bedrail assembly 300 may be
utilized as a "shelf" for use with the furniture unit 10.
[0107] The bedrail assembly 300 may include a splice member 302 and
one or more of the shelves 18, 18a, 18b, 18c, 18d, 18e or one or
more of the bedrails 18f, 18g, 18h. In this regard, while the
bedrail assembly 300 is generally shown and described as including
two of the bedrails 18f, it will be appreciated that the bedrails
18f of the bedrail assembly 300 may be replaced with one or more of
the shelves 18, 18a, 18b, 18c, 18d, 18e or one or more of the
bedrails 18f, 18g, 18h within the scope of the present disclosure.
Accordingly, while article 300 is generally shown and described
herein as being a "bedrail assembly 300" it will be appreciated
that article 300 may be utilized in various ways within the scope
of the present disclosure. For example, the bedrail assembly 300
may be utilized as a "shelf assembly" for use with the furniture
unit 10.
[0108] The splice member 302 may be formed from wood, metal,
polymer, or other suitable structural material and may define a
cross-sectional shape that is substantially the same as a void
defined by the shelves 18, 18a, 18b, 18c, 18d, 18e or the bedrails
18f, 18g, 18h. For example, the cross-sectional shape of the splice
member 302 may be substantially the same as the shape of the void
defined by the hollow distal support 216f of the bedrail 18f. In
this regard, the void may be defined by the lower surface 56 of the
base layer 48. The cross-sectional size of the void defined by the
surface 56 of the base layer 48 may be smaller or larger than the
cross-sectional size of the splice member 302.
[0109] Assembling the bedrail assembly 300 may include placing the
splice member 302 within the hollow distal support 216f of two
bedrails 18f (e.g., FIG. 13A) and moving a first of the bedrails
18f toward the second of the bedrails 18f. For example, assembling
the bedrail assembly 300 may include moving a first of the bedrails
18f toward the second of the bedrails 18f until an end 26h of the
first of the bedrails 18f abuts an end 28h of the second of the
bedrails 18f. If the cross-sectional size of the void defined by
the surface 56 of the base layer 48 is smaller than the
cross-sectional size of the splice member 302, the splice member
302 may be disposed within the void in a friction-fit arrangement.
The splice member 302 can increase the strength and rigidity of the
bedrails 18f and the bedrail assembly 300.
[0110] The configuration of, and related methods of manufacturing,
the furniture unit 10 described herein, including, for example, the
various channels 202, and the seams 104-n and folds 106-n formed
thereby, can allow a user to easily and efficiently manufacture the
shelves 18, 18a, 18b, 18c, 18d, 18e, the bedrails 18f, 18g, 18h,
the furniture unit 10, and the bedrail assembly 300 to have
superior strength and durability.
[0111] With reference to FIG. 15, another furniture unit 410 is
shown. While the furniture unit 410 is generally shown and
described herein as being a table, it will be appreciated that the
furniture unit 410, or parts thereof, may include, or otherwise be
utilized as, other types of home or office furniture or fixtures
(e.g., shelves, bed frames, desks, etc.) within the scope of the
present disclosure. The structure, function, and method of
manufacturing the furniture unit 410 may be substantially similar
to that of the shelves 18, 18a, 18b, 18c, 18d, 18e, the bedrails
18f, 18g, 18h, the furniture unit 10, and the bedrail assembly 300,
apart from any exceptions described below and/or shown in the
Figures. Accordingly, the structure and/or function of similar
features will not be described again in detail. In addition, like
reference numerals are used hereinafter and in the drawings to
identify like features.
[0112] The furniture unit 410 may include a shelf 418 and one or
more legs 422 coupled to, or otherwise supported by, the shelf 418.
The shelf 418 may be substantially similar to the shelf 18. With
reference to FIGS. 16-18, the legs 422 may each define a
substantially hollow construct extending from a proximal end 424 to
a distal end 426 and including, or otherwise formed from, the
substrate 46, including the base layer 48 and the upper laminate
layer 50. With reference to FIGS. 17-19, the substrate 46 may
further include a plurality of proximal segments 428-1, 428-2, . .
. 428-n, a plurality of distal segments 430-1, 430-2, . . . 430-n,
a proximal end segment 432, and a distal end segment 434. While the
substrate 46 is generally shown and described herein as including
four proximal segments 428-1, 428-2, 428-3, 428-4 and four distal
segments 430-1, 430-2, 430-3, 430-4, it will be appreciated that
the substrate 46 may include more or less than four proximal
segments 428-1, 428-2, 428-3, 428-4 and four distal segments 430-1,
430-2, 430-3, 430-4 within the scope of the present disclosure.
[0113] As illustrated in FIG. 19, the substrate 46 may further
include a plurality of the primary channels 202 and a plurality of
secondary channels 436. As previously described, each primary
channel 202 may be defined by the first channel wall 204, having
one of the male portion 207 or the female portion 209, and the
second channel wall 206 having the other of the male portion 207 or
the female portion 209 and forming the common edge 208 with the
first channel wall 204. In particular, each proximal segment 428-1,
428-2, . . . 428-n may include the first channel wall 204 disposed
on a first side of the proximal segment 428-1, 428-2, . . . 428-n,
and the second channel wall 206 disposed on a second side, opposite
the first side, of the proximal segment 428-1, 428-2, . . . 428-n,
such that the common edge 208 is disposed between adjacent pairs of
the proximal segments 428-1, 428-2, . . . 428-n. As will be
explained in more detail below, each proximal segment 428-1, 428-2,
. . . 428-n may be hingedly coupled to an adjacent proximal segment
428-1, 428-2, . . . 428-n along the common edge 208. Each distal
segment 430-1, 430-2, . . . 430-n may similarly include the first
channel wall 204 disposed on a first side of the distal segment
430-1, 430-2, . . . 430-n, and the second channel wall 206 disposed
on a second side, opposite the first side, of the distal segment
430-1, 430-2, . . . 430-n. Likewise, each of the proximal and
distal end segments 432, 434 may include the first and second
channel walls 204, 206 disposed on opposed first and second sides
of the proximal and distal end segments 432, 434, and the first and
second channel walls 204, 206 disposed on opposed third and fourth
sides of the proximal and distal end segments 432, 434.
[0114] Each primary channel 202 may form an angle .delta. with an
adjacent primary channel 202. In particular, each common edge 208
(FIGS. 14A and 20), disposed between two of the proximal segments
428-1, 428-2, . . . 428-n may form the angle .delta. with the
common edge 208 disposed between another two of the proximal
segments 428-1, 428-2, . . . 428-n. The angle .delta. may be
between zero degrees (e.g., such that each primary channel 202,
each common edge 208, or each first channel wall 204 is parallel
with one or more others of the primary channels 202, common edges
208, or first channel walls 204) and eighty degrees. In some
implementations, the angle .delta. is between one degree and ten
degrees. In some implementations, the angle .delta. is
substantially (e.g., +/-three degrees) equal to five degrees, such
that a distance between the first and second channel walls 204, 206
of each proximal segment 428-1, 428-2, . . . 428-n decreases in the
direction extending from the distal end 426 towards the proximal
end 424.
[0115] Each secondary channel 436 may be defined by a first channel
wall 438, a second channel wall 440, and a floor 442 extending
between the first and second channel walls 438, 440. In some
implementations, the first channel wall 438, the second channel
wall 440, and the floor 442 may define a substantially U-shaped
channel 436. As illustrated in FIG. 19, the first channel wall 438
may be disposed on an end of one of the proximal segments 428-1,
428-2, . . . 428-n, while each second channel wall 440 may be
disposed on an end of one of the distal segments 430-1, 430-2, . .
. 430-n that is adjacent to one of the proximal segments 428-1,
428-2, . . . 428-n, such that the floor 442 extends between
adjacent proximal segments 428-1, 428-2, . . . 428-n and distal
segments 430-1, 430-2, . . . 430-n. As will be explained in more
detail below, each distal segment 430-1, 430-2, . . . 430-n may be
hingedly coupled to an adjacent proximal segment 428-1, 428-2, . .
. 428-n along the floor 442.
[0116] Each secondary channel 436 may form an angle .mu. with an
adjacent secondary channel 436. In particular, each first channel
wall 438, second channel wall 440, or floor 442 disposed between
one of the proximal segments 428-1, 428-2, . . . 428-n and one of
the distal segments 430-1, 430-2, . . . 430-n may form the angle
.mu. with the first channel wall 438, second channel wall 440, or
floor 442 disposed between another adjacent ones of the proximal
segments 428-1, 428-2, . . . 428-n and distal segments 430-1,
430-2, . . . 430-n. The angle .mu. may be between one hundred
eighty degrees (e.g., such that each secondary channel 436, each
floor 442, or channel wall 438, 440 is parallel with one or more
others of the secondary channels 436, floors 442, or channel walls
438, 440) and two hundred sixty degrees. In some implementations,
the angle .mu. is substantially (e.g., +/-three degrees) equal to
one hundred eighty-five degrees.
[0117] With further reference to FIG. 19, each distal segment
430-1, 430-2, . . . 430-n may include one of the first channel wall
204 or the second channel wall 206, having one of the male portion
207 or the female portion 209, respectively. In some
implementations, the first channel wall 204 of each distal segment
430-1, 430-2, . . . 430-n may be parallel to the second channel
wall 206 of such distal segment 430-1, 430-2, . . . 430-n, and
perpendicular to the secondary channel 436 of such distal segment
430-1, 430-2, . . . 430-n, such that each distal segment 430-1,
430-2, . . . 430-n is spaced apart from each adjacent distal
segment 430-1, 430-2, . . . 430-n by a void 444.
[0118] With reference to FIGS. 16-18, in the assembled
configuration, the leg 422 may include, or otherwise define, a
plurality of proximal seams 448-1, 448-2, . . . 448-n, a plurality
of distal seams 450-1, 450-2, . . . 450-n, a plurality of
intermediate seams 452-1, 452-2, . . . 452-n, a plurality of
proximal end seams 454-1, 454-2, . . . 454-n, a plurality of distal
end seams 456-1, 456-2, . . . 456-n, a plurality of proximal folds
458-1, 458-2, . . . 458-n, a plurality of intermediate folds 462-1,
462-2, . . . 462-n, a proximal end fold 464-1, and a distal end
fold 466-1. In particular, each first channel wall 204 of a primary
channel 202 may engage the second channel wall 206 of the same of
primary channel 202, in the manner previously described, to define
a corresponding proximal seam 448-1, 448-2, . . . 448-n and
proximal fold 458-1, 458-2, . . . 458-n. Similarly, each first
channel wall 438 of a secondary channel 436 may engage the second
channel wall 440 of the same secondary channel 436 to define a
corresponding intermediate seam 452-1, 452-2, . . . 452-n and
intermediate folds 462-1, 462-2, . . . 462-n. In some
implementations, engagement of the first channel wall 438 with the
second channel wall 440 may define a void 470 (FIG. 17) at the
corresponding secondary channel 436. The first channel wall 204 of
each distal segment 430-1, 430-2, . . . 430-n may engage the second
channel wall 206 of an adjacent distal segment 430-1, 430-2, . . .
430-n, in the manner previously described, to define a
corresponding distal seam 450-1, 450-2, . . . 450-n.
[0119] With reference to FIG. 17, in the assembled configuration,
the leg 422 may include a proximal portion 472 and a distal portion
474. The proximal portion 472 may be formed by the proximal
segments 428-1, 428-2, . . . 428-n and may define a varying
cross-sectional area in a plane extending parallel to the
intermediate seams 452-1, 452-2, . . . 452-n. For example, the
proximal portion 472 may define a multi-sided pyramidal shape
extending between the proximal and distal ends 432, 434 of the leg
422. In particular, outer surfaces 476 (FIG. 16) of proximal
segments 428-1, 428-2, . . . 428-n may collectively define a
pyramidal shape. Similarly, inner surfaces 477 (FIG. 17) of
proximal segments 428-1, 428-2, . . . 428-n may collectively define
a pyramidal shape. The distal portion 474 may be formed by the
distal segments 430-1, 430-2, . . . 430-n and may define a uniform
cross-sectional area (e.g., the same cross-sectional size and shape
across the entire distal portion 474) in a plane extending parallel
to the intermediate seams 452-1, 452-2, . . . 452-n. For example,
the distal portion 474 may define a rectangular shape extending
from the distal end 434 to the channel 436 of the leg 422. In
particular, outer surfaces 478 (FIG. 16) of the distal segments
430-1, 430-2, . . . 430-n may collectively define a cuboid shape.
Similarly, inner surfaces 479 (FIG. 17) of the distal segments
430-1, 430-2, . . . 430-n may collectively define a cuboid
shape.
[0120] With reference to FIGS. 14A-14D and 20-22, a method of
manufacturing and assembling the leg 422 will now be described. The
method of manufacturing the leg 422 may be substantially similar to
the previously-described method of manufacturing the shelf 18.
Accordingly, certain aspects of manufacturing the leg 422 may not
be described again in detail. With particular reference to FIGS.
14A and 20, the method may include using the tool 200 to form the
primary channels 202 in the substrate 46 to define the plurality of
proximal segments 428-1, 428-2, . . . 428-n in the manner
previously described relative to the shelf 18. In this regard, the
primary channels 202 may extend through the base layer 48 and
terminate at or before the laminate layer 50.
[0121] As illustrated in FIG. 20, in some implementations, the
substrate 46 includes a first portion 46a having a plurality of
primary channels 202 forming a first plurality of proximal segments
428-1, 428-2, . . . 428-n, and a second portion 46b having a
plurality of primary channels 202 forming a second plurality of
proximal segments 428-1, 428-2, . . . 428-n. In this regard, while
the substrate 46 is shown as including a first portion 46a and a
second portion 46a, it will be appreciated that the substrate 46
may include any number of portions (e.g., 46a, 46b) within the
scope of the present disclosure.
[0122] The primary channels 202 of the first plurality of proximal
segments 428-1, 428-2, . . . 428-n may be formed such that a
proximal end 480a of the first plurality of proximal segments
428-1, 428-2, . . . 428-n of the first portion 46a is disposed
opposite a proximal end 480b of the second plurality of proximal
segments 428-1, 428-2, . . . 428-n of the second portion 46b, and a
distal end 482a of the first plurality of proximal segments 428-1,
428-2, . . . 428-n of the first portion 46a is disposed opposite a
distal end 482b of the second plurality of proximal segments 428-1,
428-2, . . . 428-n of the second portion 46b. In other
implementations, the method may include using the tool 200 to form
primary channels 202 defining the plurality of distal segments
430-1, 430-2, . . . 430-n, the proximal end segment 432, and the
distal end segment 434, as illustrated in FIG. 19. In this regard,
the method may further include providing the tool 210 (e.g, a
router, circular or reciprocating saw blade, or other suitable
cutting tool) to form the secondary channels 436 in the substrate
46. The secondary channels 436 may extend through the base layer 48
and terminate at or before the laminate layer 50.
[0123] With reference to FIG. 21, the method may also include
separating the first portion 46a of the substrate 46 from the
second portion 46b of the substrate. For example, the method may
include separating the first portion 46a from the second portion
46a by cutting or otherwise breaking the substrate 46 along one of
the primary channels 202, such that a first wall 204 of one of the
primary channels 202 defines a peripheral edge or surface of the
portion 46a or 46b, and a second wall 206 of another of the primary
channels 202 defines another peripheral edge or surface of the same
portion 46a or 46b.
[0124] With reference to FIGS. 17 and 19, the method of assembling
the leg 422 may also include applying an adhesive within one or
more of the primary channels 202 or secondary channels 436. For
example, the method may include applying an adhesive to the first
or second channels walls 204, 206 or the male or female portions
207, 209 of the primary channels 202, or to the first channel wall
438, second channel wall 440, or floor 442 of the secondary
channels 436. In some configurations, the method may include
applying a polyvinyl acetate adhesive within the primary channels
202 and a polyurethane adhesive 486 within the secondary channels
436. In some implementations, the polyurethane adhesive 486 fills
the void 470.
[0125] With reference to FIG. 22, the method may also include
folding the first or second portion 46a, 46b of the substrate 46
such that each first channel wall 204 of a primary channel 202
engages the second channel wall 206 of the same of primary channel
202, to define the corresponding seams 448-n, 450-n, 454-n, 456-n
and folds 458-n, 462-n, 464-1, 466-1. For example, the method may
include performing a plurality of folding operations to define the
plurality of seams 448-n, 450-n, 454-n, 456-n and folds 458-n,
462-n, 464-1, 466-1. Each fold 458-n, 462-n, 464-1, 466-1 may
define, or otherwise act as, a hinge for folding the substrate 46.
Accordingly each fold 458-n, 462-n, 464-1, 466-1 may be referred to
herein as a hinge 458-n, 462-n, 464-1, 466-1. As illustrated in
FIG. 17, upon folding the proximal segments 428-1, 428-2, . . .
428-n relative to the distal segments 430-1, 430-2, . . . 430-n at
the secondary channels 436, the first and second channel walls 438,
440 and the floor 442 may define the void 470 having the adhesive
486 disposed therein. While the void 470 is illustrated as defining
a substantially triangular cross-sectional shape, it will be
appreciated that the void 470 may define other cross-sectional
shapes (e.g., an isosceles trapezoid) within the scope of the
present disclosure. In this regard, the cross-sectional shape of
the void 470 may depend on the relationship between (i) the
distance between the channel walls 438, 440 and (ii) the size and
shape (e.g., angles .delta., .mu., length, etc.) of the leg
422.
[0126] In some implementations, the folding operations, and the
plurality of seams 448-n, 450-n, 454-n, 456-n and folds 458-n,
462-n, 464-1, 466-1 defined thereby, forms a hollow intermediate
member 488 (FIG. 22) defining a polygonal cross section. For
example, as previously described, the intermediate member 488 may
be formed by the proximal segments 428-1, 428-2, . . . 428-n and
may define the intermediate member 488 having a cross-sectional
area that varies (e.g., tapers) in a plane extending parallel to a
plane defined by the intermediate seams 452-1, 452-2, . . . 452-n.
For example, the intermediate member 488 may define a pyramidal
shape extending between the proximal and distal ends 480b, 482b. In
particular, the outer surfaces 476 of the proximal segments 428-1,
428-2, . . . 428-n may collectively define a pyramidal shape. In
this regard, as illustrated in FIG. 22, in the folded
configuration, the outer or inner surfaces 476, 477 of each
proximal segment 428-1, 428-2, . . . 428-n may define a
non-parallel angle relative to a longitudinal axis L extending
between the proximal and distal ends 480b, 482b of the intermediate
member 488 and relative to the others of the outer or inner
surfaces 476, 477 of the proximal segments 428-1, 428-2, . . .
428-n. Similarly, each seam 448-n and corresponding fold 458-n may
form a non-parallel angle with the others of the seams 448-n and
folds 458-n respectively.
[0127] It will also be appreciated that, as previously described,
the intermediate member 488 may include the distal portion 474
formed by the distal segments 430-1, 430-2, . . . 430-n and
defining a cross-sectional area that is uniform (e.g., constant)
from the proximal end 480a to the distal end 482a in a plane
extending parallel to the plane defined by the intermediate seams
452-1, 452-2, . . . 452-n. For example, the distal portion 474 may
define a rectangular shape extending partially between the proximal
and distal ends 480b, 482b of the intermediate member 488. In
particular, the outer surface 478 (FIG. 16) of the distal segments
430-1, 430-2, . . . 430-n may collectively define a cuboid shape.
In this regard, in the folded configuration, the outer or inner
surfaces 478, 479 of each distal segment 430-1, 430-2, . . . 430-n
may define a parallel angle relative to the longitudinal axis L
extending between the proximal and distal ends 480b, 482b of the
intermediate member 488 and relative to the others of the outer or
inner surfaces 478, 479 of the distal segments 430-1, 430-2, . . .
430-n. Similarly, each seam 450-n may form a parallel angle
relative to the others of the seams 450-n. Accordingly, with
reference to FIGS. 17 and 19, the method of manufacturing the leg
422 422, 422i may include engaging each first channel wall 438 with
the second channel wall 440 of the same secondary channel 436 to
form the void 470, and engaging the first or second channel wall
204, 206 of one or more of the proximal segments 428-1, 428-2, . .
. 428-n or distal segments 430-1, 430-2, . . . 430-n with the first
or second channel wall 204, 260 of the proximal end segment 432 or
the distal end segment 434.
[0128] With reference to FIGS. 16 and 23, the method may also
include removing the proximal end 480b or distal end 482b of the
intermediate member 488 to form a hollow furniture unit, such as
the leg 422 (FIG. 16) or the leg 422i (FIG. 23). For example, the
method may including cutting the substrate 46 to remove the
proximal end 480b or the distal end 482b. With reference to FIG.
15, the method may further include coupling the shelf 18 to the
legs 422 or 422i.
[0129] The foregoing description has been provided for purposes of
illustration and description. It is not intended to be exhaustive
or to limit the disclosure. Individual elements or features of a
particular configuration are generally not limited to that
particular configuration, but, where applicable, are
interchangeable and can be used in a selected configuration, even
if not specifically shown or described. The same may also be varied
in many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *