U.S. patent application number 16/232557 was filed with the patent office on 2019-05-30 for quick assembly furniture.
This patent application is currently assigned to AGIO INTERNATIONAL CO., LTD.. The applicant listed for this patent is AGIO INTERNATIONAL CO., LTD.. Invention is credited to Martin de Blois, ChuangXin Lin.
Application Number | 20190159590 16/232557 |
Document ID | / |
Family ID | 66634629 |
Filed Date | 2019-05-30 |
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United States Patent
Application |
20190159590 |
Kind Code |
A1 |
Lin; ChuangXin ; et
al. |
May 30, 2019 |
QUICK ASSEMBLY FURNITURE
Abstract
A kit is provided that, when assembled, forms a unit of
furniture. The kit includes side panels that can rotate about the z
axis along the hinge and which have one or more support surfaces to
support a base panel. A top panel is connected to the side panels
and back panel by a plurality of position members. The kit
comprises a plurality of flexible fasteners to reverse-ably lock
the side panels to the base panel and to lock the side panels to
the top panel and restrict the side panels from z-axis rotation and
restrict the base panel and top panel from y-axis rotation. Also
provided are methods of assembling and manufacturing the unit of
furniture.
Inventors: |
Lin; ChuangXin; (Guangdong
Province, CN) ; de Blois; Martin; (Gallatin,
TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AGIO INTERNATIONAL CO., LTD. |
Tsimshatsui East Kowloon |
|
HK |
|
|
Assignee: |
AGIO INTERNATIONAL CO.,
LTD.
Tsimshatsui East Kowloon
HK
|
Family ID: |
66634629 |
Appl. No.: |
16/232557 |
Filed: |
December 26, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15399367 |
Jan 5, 2017 |
|
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16232557 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B 63/00 20130101;
A47B 33/00 20130101; A47B 47/0075 20130101; A47B 3/06 20130101;
A47B 43/00 20130101; A47B 55/00 20130101; A47B 61/003 20130101;
A47B 2200/12 20130101; A47B 2230/13 20130101; A47F 10/06
20130101 |
International
Class: |
A47B 43/00 20060101
A47B043/00; A47B 47/00 20060101 A47B047/00 |
Claims
1. A kit that, when assembled, forms a unit of furniture, the kit
comprising: a back panel, a top panel, a base panel, and two side
panels that, when assembled, form a case, the case defining a
storage volume having a height along a y-axis, a width along an
x-axis, and a thickness along a z-axis; a plurality of position
members; wherein the side panel defines at least one upwardly
facing support surface extending along an x-z plane; wherein the
back panel is configured to extend along an x-y plane, the back
panel having a top, a bottom, and two sides; wherein each of the
side panels has a top, a bottom, and two sides and is attached to
an opposing side of the back panel by a folding hinge at a side of
the side panel, wherein the side panels are configured to rotate
about the y axis along the hinge from a closed position
substantially parallel to the back panel to an open position that
extends along a y-z plane; wherein each of the side panels is
configured to define at least one position member receptacle on the
top of the side panel, with the plurality of position members
configured to extend along the y-axis when installed into the top
of the side panels; wherein the base panel, upon assembly, is
configured to extend along an x-z plane, and the base panel may be
positioned on top of the support surface and between the side
panels; wherein the top panel, upon assembly, is configured to
extend along an x-z plane, positioned on top of the side panels,
wherein the top panel upon assembly may be connected to the side
panels by the plurality of position members installed into the top
of the side panels and a bottom surface of the top panel, and
wherein the position members restrict the top panel from relative
movement along the x and z axes; and a plurality of pre-installed
flexible fasteners, wherein a toggle portion of the fasteners is
mounted to the side panel and at least one hook portion of a
fastener is mounted to an outer surface of the base panel such that
the fastener interacts in an x-z plane, and at least one hook
portion is mounted to an inner surface of the top panel such that
the fastener interacts in the y-z plane, and wherein the toggle
portions reversibly attach to the plurality of hook portions to
lock the side panels to the base panel and to lock the side panels
to the top panel and to restrict the side panels from relative
rotation about the y-axis and restrict the base panel and top panel
from y-axis movement relative to the side panels.
2. The kit of claim 1, wherein the fastener comprises a spring
loaded toggle latch such that the unit is resilient upon loading
and unloading such that the fastener provides a flexibility in its
range of motion.
3. The kit of claim 1, wherein the position member is selected from
the group consisting of a pin, a biscuit, a dowel, and a
spline.
4. The kit of claim 1, wherein the back panel further comprises at
least one position member receptacle proximate a top surface, and
the kit is further configured such that at least one position
member may be installed into the back panel.
5. The kit of claim 4, wherein the position members may be
removably installed.
6. The kit of claim 1, wherein the support surface is defined by a
support plate affixed to a lower portion of the side panel.
7. The kit of claim 6, wherein the support plate is removably
affixed to the side panel.
8. The kit of claim 1, wherein the width of the side panels is
equal to or less than one half of the width of the back panel.
9. The kit of claim 1 wherein upon assembly the side panels swing
away from the back panel by rotation along the y axis, and wherein
the side panels may be substantially parallel to each other and
extend along the y-z plane when the fasteners are locked.
10. The kit of claim 1, wherein the kit comprises one or more
shelves extending along an x-z plane and wherein, upon assembly,
the one or more shelves is removably attached to an inside portion
of the side panels.
11. The kit of claim 1, further comprising one or more door panels
that, upon assembly, extend along an x-y plane when closed so as to
seal all or a portion of the case storage volume, and wherein the
one or more door panels may be pivotally attached to a front
portion of the side panels when assembled.
12. The kit of claim 1, wherein the unit is selected from the group
consisting of a book shelf, a storage shelf, a cabinet, a bar
table, an armoire, a case, a chiffonier, a closet, a dresser, a
locker, a wardrobe, a case, a bin, a vault, a buffet, and a
sideboard.
13. The kit of claim 1, wherein the panels are manufactured from a
material selected from the group consisting of MDF, plywood,
hardboard, wood, metal, and plastic.
14. A method of manufacturing a kit that is designed, when
assembled, to form a unit of furniture, the method comprising:
providing a back panel, a top panel, a base panel, and two side
panels that, when assembled, form a case, the case defining a
storage volume having a height along an y-axis, a width along an
x-axis, and a thickness along a z-axis, wherein the back panel is
configured to extend along an x-y plane, the back panel having a
top, a bottom, and two sides, and wherein each of the two side
panels has a top, a bottom, and two sides; attaching the side
panels to opposite ends of the back panel along a y-axis by a
plurality of folding hinges along the sides of the side panels,
wherein the side panels may be in a closed position substantially
parallel to the back panel, and wherein the side panels may be
rotated on the y axis and configured so as to unfold to an open
position such that the side panels may extend along a y-z plane,
substantially parallel to each other, and at right angles to the
back panel, the tops of the side panels and back panel forming a
contiguous top surface in an x-z plane; providing at least one
rigid support plate, the lower portions of the side panels facing
the back panel when in a closed position and the at least one rigid
support plate extending along an x-z plane when affixed to the
lower portion of the side panel and the side panels are in the open
position; providing a plurality of position members, wherein the
top surface of the side panels and back panel are configured to
define position member receptacles, the position members configured
along the y-axis when installed into the position member
receptacles; providing a plurality of flexible fasteners; wherein
the base panel is configured on assembly to be placed on top of at
least one rigid support plate so as to extend along the x-z plane;
providing a top panel configured on assembly to be placed over a
top portion of the side panels and back panel, wherein the top
panel defines position member receptacles and is configured to be
connected to the side panels by the plurality of position members
when installed into the top of the side panels; wherein the side
panels are configured to define toggle receptacles at a point
proximate an outer surface of the base panel when installed and
configured to interact in an x-z plane, and at a point proximate to
an inner surface of the top panel when installed, and wherein the
base panel is configured to define at least one hook receptacle on
a lower portion of the base panel, and the top panel is configured
to define at least one hook receptacle on a lower portion of the
top panel; and wherein when hook and toggle fasteners are
configured such that when the base panel is placed over the tops of
the rigid support plates and the top panel is placed over the tops
of the side panels and back panel, the hook and toggle fasteners
are capable of alignment so as to lock the base panel to the side
panels and to lock the top panel to the side panels.
15. The method of claim 14, further comprising providing one or
more shelves, and wherein the kit is configured so that the one or
more shelves may be attached to an inside portion of the two side
panels.
16. The method of claim 14, further comprising providing one or
more door panels that, upon assembly, are configured to be
pivotally attached to the front portion of the side panels.
17. The method of claim 14, wherein the fastener comprises a spring
loaded toggle latch such that an assembled unit is resilient upon
loading and unloading such that the fastener provides a flexibility
in its range of motion.
18. The method of claim 14, wherein the back panel defines at least
one position member receptacle within the contiguous top
surface.
19. A unit of furniture comprising: a back panel, a top panel, a
base panel, and two side panels that, when assembled, form a case,
the case defining a storage volume having a height along a y-axis,
a width along an x-axis, and a thickness along a z-axis; a
plurality of position members; wherein the side panel defines at
least one upwardly facing support surface extending along an x-z
plane; wherein the back panel is configured to extend along an x-y
plane, the back panel having a top, a bottom, and two sides;
wherein each of the side panels has a top, a bottom, and two sides
and is attached to an opposing side of the back panel by a folding
hinge at a side of the side panel, wherein the side panels are
configured to rotate about the y axis along the hinge from a closed
position substantially parallel to the back panel to an open
position that extends along a y-z plane; wherein each of the side
panels is configured to define at least one position member
receptacle on the top of the side panel, with the plurality of
position members configured to extend along the y-axis when
installed into the top of the side panels; wherein the base panel,
upon assembly, is configured to extend along an x-z plane, and the
base panel may be positioned on top of the support surface and
between the side panels; wherein the top panel, upon assembly, is
configured to extend along an x-z plane, positioned on top of the
side panels, wherein the top panel upon assembly may be connected
to the side panels by the plurality of position members coupled to
the top of the side panels and a bottom surface of the top panel,
and wherein the position members restrict the top panel from
relative movement along the x and z axes; wherein the top panel has
a reinforced edge proximate an outer edge of the top panel and at
least one support beam coupled to an inner surface of the top
panel, the side panel configured to fit between the support beam
and the reinforced edge of the top panel; and
20. a plurality of pre-installed flexible fasteners, wherein a
toggle portion of the fasteners is mounted to the side panel and at
least one hook portion of a fastener is mounted to the base panel,
and at least one hook portion is mounted to the top panel, and
wherein the toggle portions reversibly attach to the plurality of
hook portions to lock the side panels to the base panel and to lock
the side panels to the top panel and to restrict the side panels
from relative rotation about the y-axis and restrict the base panel
and top panel from y-axis movement relative to the side panels. The
unit of furniture of claim 19, wherein a single flexible fastener
is used to couple each side panel to the base panel.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 15/399,367, filed Jan. 5, 2017, the disclosure
of which is hereby interpreted in its entirety by reference.
STATEMENT REGARDING GOVERNMENT SUPPORT
[0002] None.
FIELD
[0003] The present disclosure relates to quick assembly furniture,
and more particularly to shelving or storage units wherein the side
panels are connected to the back panel by folding hinges that can
be locked into open positions via flexible fasteners. This
configuration eliminates the need for any tools or know-how for
assembly, and greatly enhances the packing efficiency and ease of
assembly and disassembly of the unit.
BACKGROUND
[0004] Quick assembly furniture has become quite popular.
Manufacturers of such furniture are called upon to offer
inexpensive and easy-to-assemble furniture to consumers. Some
furniture demanded by consumers, such as shelving or storage units,
can be quite bulky and require a large amount of space in order to
be shipped pre-assembled. In an effort to provide cost savings to
consumers, manufacturers of quick assembly furniture seek ways to
ship the furniture as inexpensively as possible.
[0005] In order to keep shipping costs down, furniture is typically
shipped in multiple components that must be assembled by the
consumer upon arrival. A shipment of multiple components of
furniture may create problems. At times, components may
inadvertently be left out of the shipping box when it is shipped.
The packaging of the furniture may be damaged during shipping,
resulting in tears to the shipping box and the loss of smaller
components or the directions. Because the consumer must attach the
hardware to the furniture components, the consumer is generally
required to use tools and must, at times, follow complicated
assembly instructions. Assembly performed by the consumer may not
be as stable as factory assembly, due to the superior capabilities
of factory assembly tools relative to the capabilities of tools
normally available to or used by consumers. Additionally, once the
furniture is assembled, it may be impossible or exceptionally
difficult to disassemble the furniture without damaging the
components.
[0006] FIG. 1A illustrates a conventional kit for a unit of
furniture having a back panel 101 and side panel 102 that are
assembled by an L-shaped bracket 111, nut 112, and screw 113. FIG.
1B illustrates another configuration of a back panel 101 and side
panel 102 that are assembled by an L-shaped bracket 111, and two
screws 113. FIG. 1C illustrates a third teaching in which a back
panel 101 and side panel 102 are assembled by a flat bracket 114
and two screws 113.
[0007] In all of the configurations of FIGS. 1A-C, the consumer
must possess the necessary tools to attach the back panels 101 and
side panels 102. The necessary tools may include a hammer, a drill,
a screw driver (which may be one of any size of a phillips head,
flat head, square head, star head (available from Textron Indus.,
Inc. under the Torx.RTM. name), or other shape, and a wrench (which
may be one of any size of an open-end, box-end, combination,
flare-nut, ratcheting box, socket, etc.). Further, a consumer may
need a requisite amount of physical strength to drive the screws
into some panels. Once the kit is assembled, the unit of furniture
is in its permanent final configuration, and it is only with great
difficulty and potential damage to the unit that the unit can be
disassembled.
[0008] The consumer must also possess the necessary know-how to
assemble the kit. This means being able to read and follow any
instruction manual(s) sent with the kit. At times, the instruction
manual(s) may be complicated and/or confusing. At times, the
instruction manual(s) may not be included with the kit or may be
lost during shipment. At times, the language(s) of the instruction
manual(s) may not be the language of the consumer. These situations
lead to the consumer adopting a trial-and-error method to determine
the correct configuration of the components. The consumer may waste
time and energy building the wrong configuration, or may end with a
sub-optimal unit due to less-than-optimal placement of all the
components.
[0009] Conventional approaches for a manufacturer that does not
desire to have the consumer assemble the unit using his or her own
tools and/or follow an instruction manual, is that the unit must be
assembled by the manufacturer prior to shipment. This assembly
results in increased space required for shipping, and therefore
increases costs.
[0010] A further aspect of prior art approaches is that consumers
may damage portions of the kit, either during assembly and
disassembly, or simply during the everyday use of the article of
furniture. Such articles are often fabricated using materials such
as particle board or medium density fiberboard (MDF), for example.
Conventionally, the fully assembled product is a rigid item of
furniture, suited for its designed purpose. However, these
materials of construction may be vulnerable to failure when
stresses are applied to connection points or joints. A joint is the
close securing or fastening together of two or more smooth, even
surfaces--customarily rigid. In formal furniture sold in assembled
form, joints are typically secured by dowels, dovetails, dados,
glue blocks, rabbets, etc. In kit or knock-down furniture, joints
are commonly made rigid by custom connecting fasteners, connector
bolts, or through-bolts mating with fixed nuts. A disadvantage with
this approach is that the improper positioning of fastening
elements during assembly may result in weakened connection points
or joints. In addition, rigid designs may result in the imposition
of full stress of use on even properly positioned connection points
or joints, possibly leading to failure of connections. Kit or
knock-down furniture is likely to be relocated or disassembled for
transport, and the joints are weak points. It would be desirable to
provide a kit of furniture adapted to such stress, while still
amenable to easy assembly and disassembly.
[0011] In all of the configurations of FIGS. 1A-C, the consumer
must possess the necessary tools and know-how to attach the back
panels and side panels. Improper positioning of fastening elements
during assembly may result in weakened connection points or joints.
In addition, rigid designs may result in the imposition of full
stress of use on even properly positioned connection points or
joints, possibly leading to failure of connections.
[0012] There remains a need to simplify the process of assembling
furniture while retaining the ability to ship the furniture in as
small a container as possible. There also remains a need to create
furniture that can be easily disassembled for transport to other
locations.
BRIEF SUMMARY
[0013] The present disclosure relates to a kit that, when
assembled, forms a unit of furniture. The kit comprises: a back
panel having a height along a y-axis, a width along an x-axis, and
a thickness along a z-axis; a plurality of position members;
wherein the side panel defines at least one upwardly facing support
surface extending along an x-z plane; wherein the back panel is
configured to extend along an x-y plane, the back panel having a
top, a bottom, and two sides; wherein each of the side panels has a
top, a bottom, and two sides and is attached to an opposing side of
the back panel by a folding hinge at a side of the side panel,
wherein the side panels are configured to rotate about the y axis
along the hinge from a closed position substantially parallel to
the back panel to an open position that extends along a y-z plane;
wherein each of the side panels is configured to define at least
one position member receptacle on the top of the side panel, with
the plurality of position members configured to extend along the
y-axis when installed into the top of the side panels; wherein the
base panel, upon assembly, is configured to extend along an x-z
plane, and the base panel may be positioned on top of the support
surface and between the side panels; wherein the top panel, upon
assembly, is configured to extend along an x-z plane, positioned on
top of the side panels, wherein the top panel upon assembly may be
connected to the side panels by the plurality of position members
installed into the top of the side panels and a bottom surface of
the top panel, and wherein the position members restrict the top
panel from relative movement along the x and z axes; and a
plurality of pre-installed flexible fasteners, wherein a toggle
portion of the fasteners is mounted to the side panel and at least
one hook portion of a fastener is mounted to a bottom portion of
the base panel, and at least one hook portion is mounted to a
bottom portion of the top panel, and wherein the toggle portions
reversibly attach to the plurality of hook portions to lock the
side panels to the base panel and to lock the side panels to the
top panel and to restrict the side panels from relative rotation
about the y-axis and restrict the base panel and top panel from
y-axis movement relative to the side panels.
[0014] In one embodiment, the fastener comprises a spring loaded
toggle latch such that the unit is resilient upon loading and
unloading.
[0015] In one embodiment, the position member is selected from the
group consisting of a pin, a biscuit, a dowel, and a spline.
[0016] In one embodiment, the back panel comprises at least one
position member receptacle at the top, and the kit is further
configured such that at least one position member may be installed
into the back panel.
[0017] In one embodiment, the position members may be removably
installed.
[0018] In one embodiment, the support surface is defined by a
support plate affixed to a lower portion of the side panel.
[0019] In one embodiment, the support plate is removably affixed to
the side panel.
[0020] In one embodiment, the width of the side panels is equal to
or less than one half of the width of the back panel.
[0021] In one embodiment, upon assembly the side panels swing away
from the back panel by rotation along the y-axis, and the side
panels may be substantially parallel to each other and extend along
the y-z plane when the fasteners are locked.
[0022] In one embodiment, the kit comprises one or more shelves
extending along an x-z plane and, upon assembly, the one or more
shelves is removably attached to an inside portion of the side
panels.
[0023] In one embodiment, the kit comprises one or more door panels
that, upon assembly, extend along an x-y plane when closed so as to
seal all or a portion of the case storage volume, and the one or
more door panels may be pivotally attached to a front portion of
the side panels when assembled.
[0024] In one embodiment, the unit is selected from the group
consisting of a book shelf, a storage shelf, a cabinet, a bar
table, an armoire, a case, a chiffonier, a closet, a dresser, a
locker, a wardrobe, a case, a bin, a vault, a buffet, and a
sideboard.
[0025] In one embodiment, the panels are manufactured from a
material selected from the group consisting of MDF, plywood,
hardboard, wood, metal, and plastic.
[0026] In another embodiment, the present disclosure relates to a
method of manufacturing a kit that is designed, when assembled, to
form a unit of furniture, the method comprising: providing a back
panel, a top panel, a base panel, and two side panels that, when
assembled, form a case, the case defining a storage volume having a
height along an y-axis, a width along an x-axis, and a thickness
along a z-axis, wherein the back panel is configured to extend
along an x-y plane, the back panel having a top, a bottom, and two
sides, and wherein each of the two side panels have a top, a
bottom, and two sides; attaching the side panels to opposite ends
of the back panel along a y-axis by a plurality of folding hinges
along the sides of the side panels, wherein the side panels may be
in a closed position substantially parallel to the back panel, and
wherein the side panels may be rotated on the y axis and configured
so as to unfold to an open position such that the side panels may
extend along a y-z plane, substantially parallel to each other, and
at right angles to the back panel, the tops of the side panels and
back panel forming a contiguous top surface in an x-z plane;
providing at least one support surface, wherein the side panels are
configured to define at least one upwardly facing support surface
extending along an x-z plane, wherein the support surface is
defined by a support plate affixed to a lower portion of the side
panel, providing a plurality of position members, wherein the top
surface of the side panels and back panel are configured to define
position member receptacles, the position members configured along
the y-axis when installed into the position member receptacles;
providing a plurality of hook and toggle fasteners; wherein the
base panel is configured on assembly to be placed on top of the
plurality of support plates so as to extend along the x-z plane;
providing a top panel configured on assembly to be placed over a
top portion of the side panels and back panel, wherein the top
panel defines position member receptacles and is configured to be
connected to the side panels by the plurality of position members
when installed into the top of the side panels; wherein the side
panels are configured to define toggle receptacles at a point
proximate to a lower portion of the base panel when installed and
at a point proximate to a lower portion of the top panel when
installed, and wherein the base panel is configured to define at
least one hook receptacle on a lower portion of the base panel, and
the top panel is configured to define at least one hook receptacle
on a lower portion of the top panel; and wherein when hook and
toggle fasteners are configured such that when the base panel is
placed over the tops of the side support plates and the top panel
is placed over the tops of the side panels and back panel, the hook
and toggle fasteners are capable of alignment so as to lock the
base panel to the side panels and to lock the top panel to the side
panels.
[0027] In one embodiment, the method comprises providing one or
more shelves, and the kit is configured so that the one or more
shelves may be attached to an inside portion of the two side
panels.
[0028] In one embodiment, the method comprises providing one or
more door panels that, upon assembly, are configured to be
pivotally attached to the front portion of the side panels.
[0029] In one embodiment, the fastener comprises a spring loaded
toggle latch such that an assembled unit is resilient upon loading
and unloading.
[0030] In one embodiment, the back panel defines at least one
position member receptacle within the contiguous top surface.
DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1A illustrates a prior art teaching of a front and side
panel that are assembled by an L-shaped bracket, nut, and screw.
FIG. 1B illustrates a prior art teaching of a front and side panel
that are assembled by an L-shaped bracket and two screws. FIG. 1C
illustrates a prior art teaching of a front and side panel that are
assembled by a flat bracket and two screws.
[0032] FIG. 2A illustrates the assembled kit with the reference
axes shown and labeled. FIG. 2B illustrates a cut away view of the
disassembled kit in an open configuration. FIG. 2C illustrates a
cut away view of the disassembled unit in a closed
configuration.
[0033] FIG. 3A illustrates a support plate attached to a lower
portion of the side panel that supports a base panel. FIG. 3B
illustrates the configuration of the unit upon placement of the
base panel.
[0034] FIG. 4 illustrates the position of the fasteners that
reversibly join the side panels to the base panel.
[0035] FIG. 5 illustrates the position of the top panel prior to
its placement onto the top surface of the side panels and back
panel.
[0036] FIG. 6 illustrates the position of the fasteners that
reversibly join the side panels to the top panel.
[0037] FIG. 7 provides examples of various embodiments of
fasteners.
[0038] FIG. 8 illustrates one embodiment in which shelves divide
the space of the enclosure formed by the top panel, base panel, and
side panels.
[0039] FIG. 9 illustrates one embodiment in which one door panel,
when closed, seals all or a portion of the case storage volume
formed by the top panel, base panel, and side panels.
[0040] FIG. 10 illustrates a view of the kit in which all
components are disassembled.
[0041] FIG. 11 illustrates a flow chart outlining the steps of the
method of assembly.
[0042] FIG. 12 illustrates a flow chart outlining the steps of the
method of manufacture.
DESCRIPTION
[0043] The present invention now will be described more fully with
reference to the accompanying drawings, in which embodiments of the
invention is shown. However, this invention should not be construed
as limited to the embodiments set forth herein. Rather, these
embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey the scope of the invention to
those skilled in the art.
[0044] As used herein, the term "comprising" or "comprises" is
open-ended, and includes one or more stated features, integers,
elements, steps, components or functions but does not preclude the
presence or addition of one or more other features, integers,
elements, steps, components, functions or groups thereof. As used
herein, the term "and/or" includes any and all combinations of one
or more of the associated listed items. The term "about" means the
stated value plus or minus a reasonable or conventional margin of
error of measurement, or plus or minus 10% if no method of
measurement is indicated.
[0045] As used herein, the common abbreviation "e.g.," which
derives from the Latin phrase "exempli gratia," may be used to
introduce or specify a general example or examples of a previously
mentioned item, and is not intended to be limiting of such item. If
used herein, the common abbreviation "i.e.," which derives from the
Latin phrase "id est," may be used to specify a particular item
from a more general recitation.
[0046] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a," "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise.
[0047] Well-known functions or constructions may not be described
in detail for brevity and/or clarity. Unless otherwise defined, all
terms (including technical and scientific terms) used herein have
the same meaning as commonly understood by one of ordinary skill in
the art to which this invention belongs. It will be further
understood that terms, such as those defined in commonly used
dictionaries, should be interpreted as having a meaning that is
consistent with their meaning in the context of the relevant art
and will not be interpreted in an idealized or overly formal sense
unless expressly so defined herein.
[0048] In addition, spatially relative terms, such as "under,"
"below," "lower," "over," "upper," "downward," "upward," "inward,
"outward" and the like, may be used herein for ease of description
to describe one element or feature's relationship to another
element(s) or feature(s) as illustrated in the figures. It will be
understood that the spatially relative terms are intended to
encompass different orientations of the device in use or operation
in addition to the orientation depicted in the figures. For
example, if the device in the figures is turned over, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus, the
exemplary term "under" can encompass both an orientation of over
and under. The device may be otherwise oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly.
[0049] It will be understood that when an element is referred to as
being "attached," "coupled" or "connected" to another element, it
can be directly attached, coupled or connected to the other element
or intervening elements may also be present. In contrast, when an
element is referred to as being "directly attached," directly
coupled" or "directly connected" to another element, there are no
intervening elements present. Words such as passageway, fluid path,
or flow component, etc., are intended to communicate structure
supporting fluid communication and may comprise a tube, pipe, hose,
boring, channel, etc.
[0050] The following description includes various embodiments and
method of carrying out exemplary embodiments of the present
approach. The description is not to be taken in a limiting sense,
and is made merely for the purpose of illustrating the general
principles of the present approach.
[0051] The present invention overcomes the limitations of the
conventional furniture kits that are illustrated in FIG. 1A-C. Some
embodiments have a back panel 101, two side panels 102, a base
panel 103, and a top panel 104 that, when assembled, form a unit of
furniture 140. The unit of furniture 140 uses hinges, position
members, and flexible fasteners 117 to secure the unit of furniture
140 in lieu of nails, brackets, nuts, screws, or other comparable
types of fasteners. The unit of furniture 140 may not require the
use of tools in order to assemble the unit of furniture 140.
[0052] FIG. 2 demonstrates certain advantages of the present
approach. FIG. 2A illustrates an embodiment of an assembled kit 140
with the reference axes shown and labeled. FIG. 2B illustrates a
cut away view of the kit 140 in an open configuration. In one
embodiment, the back panel 101 and side panels 102 are joined by
one or more folding hinges 115. In the open configuration of this
embodiment, the side panels 102 are at right angles to the back
panel 101 and are substantially parallel to each other. FIG. 2C
illustrates a cut away view of the kit 140 in a closed
configuration. In this embodiment, the side panels 102 are folded
in and are substantially parallel to the back panel 101. FIG. 2C is
typical of the embodiment that would be shipped to the consumer,
and FIG. 2B is typical of the embodiment that the consumer would
make by unfolding the side panels 102 away from the back panel 101.
A consumer needs to merely swing open the side panels 102 such that
they are at right angles to the back panel 101 and are
substantially parallel to each other. No tools are needed, and
little, if any, know-how is needed, as the side panels 102 can only
swing in one direction, away from the back panel 101.
[0053] The panels may be manufactured from particle board, MDF,
plywood, hardboard, wood, metal, plastic, or any other appropriate
material now known or later discovered. Each panel may be
constructed of a different material. In some embodiments, a surface
of the panels is coated in melamine. In some embodiments, the back
panel 101 may be constructed of a material different than that of
the other panels. For some manufacturers, the panels used may be
constructed from a material that is vulnerable to failure when
stresses are applied to connection points or joints. The improper
positioning of rigid joints may result in weakened connection
points or joints when stress is applied.
[0054] Each of the panels has a width. Some of the panels may have
uniform widths. In other embodiments, the back panel 101 may have a
smaller width than a width of the side panels 102. Alternately, the
back panel 101 may have a smaller width than a width of the other
panels.
[0055] FIGS. 3A and 3B demonstrate the ease of the base panel 103
assembly. FIG. 3A illustrates an upwardly facing support face
defined by at least one rigid support plate 116 affixed to a lower
portion of the side panel 102 that supports a base panel 103 at the
base of the two side panels 102. The base portions of the side
panels 102 face the back panel 101 when in a closed position and
the at least one rigid support plate 116 extends along an x-z plane
when the side panels 102 are in the open position. The at least one
rigid support plate 116 may be attached in any manner of ways known
in the art. In one embodiment, the at least one rigid support plate
116 may be welded to the lower portion of the side panel 102 by the
manufacturer. In one embodiment, the at least one rigid support
plate 116 is removably affixed to the side panel 102. FIG. 3B
illustrates the configuration of the unit upon placement of the
base panel 103 onto the one or more rigid support plates 116. A
consumer needs to merely place the base panel 103 onto the support
plates 116 that are attached to the side panels 102. No tools and
little, if any, know-how is needed.
[0056] FIG. 4 demonstrates an approach by which the unit of
furniture is made stable and yet can be assembled and disassembled
in a quick and easy manner. FIG. 4 shows a cut away view of an
embodiment of the unit and illustrates a configuration positioning
a plurality of pre-installed flexible fasteners 117 that join the
side panels 102 with the base panel 103. The flexible fasteners 117
may be installed in any manner of ways known in the art. The
fasteners 117 lock the side panels 102 with the base panel 103 at
right angles.
[0057] A toggle portion 131 of each fastener 117 may be mounted to
the base panel 103 and a hook or toggle receptacle portion 132 of
each fastener is mounted to the side panel 102. The toggle portion
131 reversibly attaches to the toggle receptacle 132 to lock the
side panels 102 to the base panel 103 and restrict the side panels
102 from z-axis rotation and restrict the base panel 103 from
y-axis rotation.
[0058] Base panel 103 has an outer surface, an inner surface, and a
length that extends across the x-axis and is defined by two
substantially parallel side edges. In some embodiments, at least
one flexible fastener 117 is coupled proximate each of the
substantially parallel side edges. In some embodiments, the
flexible fastener 117 is coupled to the outer surface of the base
panel 103. The flexible fastener 117 may further be coupled at
approximately a center point of the parallel side edges. In some
embodiments, a single flexible fastener 117 is used to couple each
side panel 102 to the base panel 103. In other embodiments, each
side 102 panel may contain a plurality of fasteners 117 that are
coupled to the base panel 103. In other embodiments, the base panel
103 is coupled to the back panel 101 using at least one flexible
fastener 117.
[0059] In embodiments where a single fastener 117 is used to couple
each side panel 102 to the base panel 103, the fastener 117 is
strategically placed and sufficiently flexible so as to allow some
flexibility without causing damage to the underlying base panel 103
or side panels 102.
[0060] Each side panel 102 has a top surface and a bottom surface
that extend across the x-axis when assembled, as shown in FIG. 5.
Each side panel 102 further has an outer surface and an interior
surface that extend across the y-axis when assembled. The interior
surfaces are configured to face the interior of a case when the
unit of furniture 140 is assembled. In some embodiments, the side
panels 102 also include legs. In some embodiments, the flexible
fastener 117 may be coupled to the bottom surface of the side
panels 102. In embodiments in which the side panels 102 do not
include legs, the flexible fastener 117 may be coupled to the
interior surface of the side panel 102 proximate the bottom
surface. The fasteners 117 may be coupled at approximately a center
point of the bottom surface of the side panels 102, as is shown in
FIG. 4. The toggle portion 131 of the flexible fastener 117 may be
positioned on the outer surface of the base panel 103 to line up
and interact with the toggle receptacle 132 of the flexible
fastener 117 on the bottom surface of the side panel 102. As can be
seen in FIG. 4, in this embodiment, the toggle portion 131 and
toggle receptacle 132 interact in an x plane. In other embodiments,
the toggle receptacle 132 may be coupled at approximately to the
interior surface of the side panel 102 proximate a center point of
the bottom surface, and the toggle portion 131 of the flexible
fastener 117 may be positioned proximate the center point of the
side edge of the base panel 103. In this embodiment, the toggle
portion 131 and toggle receptacle 132 interact in a y plane. The
fastener 117 acts to restrain relative movement of the side panels
102 with respect to the bottom panel 101 around the z-axis. The
fastener 117 also acts to restrain relative movement of the bottom
panel 101 with respect to the side panels 102 around the x-axis and
the y-axis. The fastener 117 allows the unit of furniture 140 to
use a small number of restraints such that the result of the
overall structure is rigid. This is in contrast to prior furniture
assemblies where an excessive number of rigid fasteners were used.
Not only does the reduced number of fasteners reduce costs and
avoids over-engineering, it simplifies the assembly process for the
consumer.
[0061] The toggle portion 131 and toggle receptacle 132 may be
mounted to the side panels 102 and base panel 103 by the
manufacturer. The consumer merely needs to lock the corresponding
toggle portion 131 and toggle receptacle 132 of the fastener 117
together to create a resilient, stabilized unit. In some
embodiments, the side panels 102 may be reinforced proximate the
fastener 117. In other embodiments, the base panel 103 may be
reinforced proximate the fastener 117. The side panels 102 and base
panel 103 may be reinforced with sturdier materials, increased
flexibility of the material, or any other method in the art used to
increase flexibility now known or later discovered.
[0062] Because the unit of furniture may be constructed from
materials that may be vulnerable to failure when stress is applied,
fasteners 117 that are resilient at the connection points may
mitigate the risk of failure when stress is applied.
[0063] FIG. 5 illustrates the position of the top panel 104 onto
the top surface of the side panels 102 and back panel 101. The top
panel 104 is shown connected to the side panels 102 and back panel
101 by a plurality of position members 118 mounted to a top surface
of the side panels 102 and a bottom surface of the top panel 104,
with the position members 118 oriented along the y-axis. The top
surface of the side panels 102 may have a plurality of recesses
that are configured to interact with the plurality of position
members 118. A top surface of the back panel 101 may have a
plurality of recesses that are configured to interact with the
plurality of position members. The position members 118 are shown
in the figures as pins, but other embodiments of position members,
such as biscuits, dowels, and splines may be acceptable
alternatives, depending on the application and type of furniture.
In some embodiments, the position members 118 are only coupled to
the top surface of the side panels 102 and the bottom surface of
the top panel 104. In other embodiments, the position members 118
are only coupled to the top surface of the back panel 101 and the
bottom surface of the top panel 104.
[0064] The position members 118 fit into corresponding position
member receptacles 119 on the opposite surface. The position
members 118 restrict the top panel 108 from x and z axis movement.
For this embodiment, a consumer need merely place the top panel 104
onto the top surface of the side panels 102 and back panel 101,
aligning the position members 118 with the position member
receptacles 119, to assemble the top panel 104. In some
embodiments, the position members 118 have a uniform width or
diameter. In other embodiments, the position members 118 may
increase in width as they extend upwardly, and the recesses in the
bottom surface of the top panel 104 may be keyhole recesses.
[0065] FIG. 6 illustrates the fasteners 117 that may be used to
join the side panels 102 to the top panel 104. Top panel 104 has an
outer surface, an inner surface, and a length that extends across
the x-axis and is defined by two substantially parallel side edges.
In some embodiments, the side edges of the top panel 104 may extend
beyond the outer surface of at least one of the side panels 102. In
some embodiments, the side edges of the top panel 104 extend beyond
the side panels 102.
[0066] In some embodiments, the top panel 104 has at least one
support beam coupled to the inner surface. In other embodiments,
the top panel 104 may have a reinforced edge proximate at least one
outer edge of the top panel. The reinforced edge may have an
increased width than a width of the top panel 104, and the
reinforced edge may extend downward from an outer surface of the
top panel 104 along the y-axis. In some embodiments, the reinforced
edge may extend along the perimeter of the top panel 104. The
support beams and reinforced edge may assist in mitigating failure
when stresses are applied to the top panel 104.
[0067] At least one fastener 117 may be coupled to the inner
surface of the top panel 104. In some embodiments, at least one
flexible fastener 117 is coupled proximate each of the
substantially parallel side edges of the top panel 104. In some
embodiments, the flexible fastener 117 is coupled to the inner
surface of the top panel 104. The flexible fastener 117 may further
be coupled at approximately a center point of the parallel side
edges. In some embodiments, the fastener 117 may be coupled to a
support beam. The flexible fastener 117 may be coupled to the
support beam proximate a center point of the side panel 102 when
the unit of furniture 140 is assembled.
[0068] There may be a single flexible fastener 117 used to couple
each side panel 102 to the top panel 104. In other embodiments,
each side 102 panel may contain a plurality of fasteners that are
coupled to the top panel 104. In other embodiments, the top panel
104 is coupled to the back panel 101 using at least one flexible
fastener 117. In one embodiment, a toggle portion 131 of each
fastener 117 may be mounted to the side panel 102 and a toggle
receptacle or hook portion 132 of each fastener may be mounted to
an inner surface of the top panel 104. In another embodiment, a
toggle portion 131 of each fastener 117 may be mounted to an inner
surface of the top panel 104 and a toggle receptacle or hook
portion 132 may be mounted to the side panel 102. The toggle
portion 131 reversibly attaches to the toggle receptacle or hook
portion 132 to release-ably lock the side panels 102 to the top
panel. Once fastened, the fasteners restrict the side panels 102
from z-axis rotation and restrict the top panel 104 from y-axis
rotation. The consumer merely needs to latch the toggle portion 131
to the toggle receptacle portion 132 to complete this portion of
the assembly and create a resilient, stabilized unit.
[0069] In embodiments where a single fastener 117 is used to couple
each side panel 102 to the top panel 104, the fastener 117 is
strategically placed and sufficiently flexible so as to allow some
flexibility without causing damage to the underlying base panel 104
or side panels 102. Flexibility may be desired in the event of
improper placement of the connection points.
[0070] In some embodiments, the flexible fastener 117 may be
coupled to the interior surface of the side panels 102. The
fasteners 117 may be coupled proximate a center point of the top
surface of the side panels 102. The toggle receptacle 132 of the
flexible fastener 117 may be positioned on the inner surface of the
top panel 104 to line up and interact with the toggle portion 131
of the flexible fastener 117 on the bottom surface of the side
panel 102. In this embodiment, the toggle portion 131 and toggle
receptacle 132 interact in a y plane. The fastener 117 acts to
restrain relative movement of the side panels 102 with respect to
the top panel 104 around the z-axis. The fastener 117 also acts to
restrain relative movement of the top panel 104 with respect to the
side panels 102 around the x-axis and the y-axis. The fastener 117
allows the unit of furniture 140 to use a small number of
restraints such that the result of the overall structure is rigid.
This is in contrast to prior furniture assemblies where an
excessive number of rigid fasteners were used. Not only does the
reduced number of fasteners reduce costs and avoids
over-engineering, it simplifies the assembly process for the
consumer.
[0071] The toggle portion 131 and toggle receptacle 132 may be
mounted to the side panels 102 and top panel 104 by the
manufacturer. The consumer merely needs to lock the corresponding
toggle portion 131 and toggle receptacle 132 of the fastener 117
together to create a resilient, stabilized unit. In some
embodiments, the side panels 102 may be reinforced proximate the
fastener 117. In other embodiments, the top panel 104 may be
reinforced proximate the fastener 117. The side panels 102 and top
panel 104 may be reinforced with sturdier materials, increased
flexibility of the material, or any other method in the art used to
increase flexibility now known or later discovered.
[0072] In some embodiments, the top surface of the side panel 102
is configured to fit between a support beam and a reinforced edge
of the top panel 104. In addition to using the position members 118
and the fasteners 117 to attach the top panel 104 to the side
panels 102 and back panel 101, the support beam and reinforced edge
may act to stabilize the side panels 102 and restrict movement of
the side panels 102 relative to the z-axis. In some embodiments,
the side panel 102 is lodged between the reinforced edge and a
support beam of the top panel 104.
[0073] FIG. 7 illustrates various embodiments of the flexible hook
and toggle fasteners 117. The fasteners 117 may include a toggle
portion 131 that is spring loaded 133, which provides constant
tension for secure latching. A spring loaded toggle latch 133 makes
the unit resilient upon loading and unloading due to its
flexibility in range of motion. "Resilient" may be defined as
fastening that permits a minor deformation at the joint, with the
ability to return to shape after loading, but not so rigid as to
damage the surrounding furniture material to which the fastener is
mounted, as might occur with a glued or otherwise rigid joint of
MDF, for example. As mentioned above, resiliency is important if
the unit of furniture is constructed from materials that may be
vulnerable to failure when stress is applied. "Deformation" in this
context involves both extension and compression along the axis of
any spring within fastener 117, but also rotation of the latching
ring 142 about its mount on toggle portion 131 or about its
connection point on toggle receptacle portion 132. Thus, the degree
of resilience desired is a function of the specifications of any
springs, as well as the relation of latching ring 142 to its mount
or connection point design.
[0074] In some embodiments, the fastener 117 may include a hasp. In
other embodiments, the fastener 117 does not include a hasp. In
embodiments where the fastener 117 does not include a hasp, the
toggle portion 131 and the toggle receptacle 132 interact in a
manner to sufficiently fasten the fastener 117 without the use of a
hasp or additional fastening mechanism. The fastener 117 may
further be sufficiently flexible so that, in the event of operator
error in appropriately aligning the panels, the panels may not
deform when the fastener 117 is employed.
[0075] Optionally, one or more shelves 105 may be included to
divide the case storage volume formed by the top panel 104, base
panel 103, and side panels 102, as is shown in FIG. 8. The one or
more shelves 105 are generally attached to the inside portion of
the side panels 102 such that the shelves 105 extend along an x-z
plane and are positioned between the side panels 102. The one or
more shelves 105 can be attached in any manner of ways known in the
art. In some embodiments, the one or more shelves 105 are coupled
to the unit of furniture using flexible fasteners 117. In some
embodiments, the one or more shelves 105 are coupled to the toggle
portion 131, and the rear panel 101 is coupled to the toggle
receptacle 132.
[0076] Optionally, one or more door panels 106 may be included to
seal off all or a portion of the case storage volume formed by the
top panel 104, the base panel 103, and the side panels 102, as is
shown in FIG. 9. The one or more door panels 106 can be attached in
any manner of ways known in the art. In some embodiments, the one
or more door panels 106 are coupled to the unit of furniture using
flexible fasteners 117. FIG. 9 shows one embodiment in which one
door panel 106 closes off the space of the enclosure.
[0077] FIG. 10 illustrates a view of the kit with all of the
components disassembled. A consumer may receive this arrangement in
a shipped kit.
[0078] FIG. 11 illustrates a flow chart outline of the steps of the
method of assembly. The method of assembly may illustrate how to
assemble the unit of furniture 140 described above. These steps
illustrate the information that may be found on a kit assembly
instruction page or manual. In the first step, a consumer unfolds
the side panels 102 away from the back panel 101 such that the side
panels 102 are substantially parallel to each other and are at
right angles to the back panel 101. In the next step, the consumer
attaches the base panel 103 by positioning the base panel 103 onto
the one or more rigid support plates 116 between the side panels
102. In the next step, the consumer attaches the top panel 104 by
aligning position members 118 with position member receptacles 119
in the side panels 102 and top panel 104. Next, the consumer
connects the complimentary flexible fastener 117 components to lock
the side panels 102 to the base panel 103 and to lock the side
panels 102 to the top panel 104. Optionally, the consumer may
attach one or more shelves 105 to the inside portion of the side
panels 102. Optionally, the consumer may attach one or more door
panels 106 to a front portion of the side panels 102. FIG. 12
illustrates a flow chart outline of the steps of a process or
method for manufacturing the kit 140 that, when assembled, forms a
unit of furniture. In the first step, a manufacturer provides 201 a
back panel 101, top panel 104, base panel 103, and two side panels
102 that, when assembled, form a case defining a storage volume. In
the next step, the side panels 102 are attached 202 to opposite
ends of the back panel 101 by a plurality of folding hinges 115
mounted along the sides of the side panels 102. In the next step,
at least one rigid support plate 116 is provided 203 which can be
installed into a lower portion of the side panels 102. In the next
step, a manufacturer provides 204 a plurality of position members
118 which may be reversibly installed into a plurality of position
member receptacles 119 defined by the top surface of the side
panels 102 and back panel 101. In the next step, a manufacturer
installs 205 a plurality of flexible fasteners 117, wherein the
flexible fasteners 117 are configured such that when the base panel
103 is placed over the tops of the one or more rigid support plates
116 and the top panel 104 is placed over the tops of the side
panels 102 and back panel 101, the toggle portion 131 and hook
portion 132 of the flexible fasteners 117 are capable of alignment
so as to lock the base panel 103 to the side panels 102 and to lock
the top panel 104 to the side panels 102. Optionally, a
manufacturer may provide 210 one or more shelves 105 that may be
attached to an inside portion of the two side panels 102.
Optionally, a manufacturer may provide 220 one or more door panels
106 that may be pivotally attached to a front portion of the side
panels 102. Further, a manufacturer may provide such alternative
embodiments of kit 140 described herein.
[0079] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the approach. As used herein, the singular forms "a," "an," and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
[0080] The present approach may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The disclosed embodiments are therefore to be considered
in all respects as illustrative and not restrictive, the scope of
the present approach being indicated by the claims of the
application rather than by the foregoing description, and all
changes which come within the meaning and range of equivalency of
the claims are therefore intended to be embraced therein. One of
ordinary skill in the art should appreciate that numerous
possibilities are available, and that the scope of the present
approach is not limited by the embodiments described herein.
* * * * *