US20200146444A1

US20200146444A1 - Construction system and method and related articles

Info

Publication number: US20200146444A1
Application number: US16/744,411
Authority: US
Inventors: Marvin K. Burnett; Troy E. Tedrow; Ronald J. Salsbury; Mark R. Hopper
Original assignee: Sauder Woodworking Co
Current assignee: Sauder Woodworking Co
Priority date: 2017-01-17
Filing date: 2020-01-16
Publication date: 2020-05-14
Also published as: US20190125076A1; US10201226B2; CA3123648A1; CA2991463A1; US10617204B2; CA2991463C; CA3123659A1; CA3123659C; US20180199707A1

Abstract

A drawer assembly includes a bottom, a first side extending from the bottom, and a second side extending from the bottom and opposite the first side. The second side includes a first wall portion and a second wall portion opposite the first wall portion. The first wall portion is spaced apart from the second wall to define a first cavity therebetween. The first wall portion includes a first aperture in fluid communication with the first cavity.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a continuation-in-part of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 14/233,669, filed on Dec. 27, 2018, which is a divisional of U.S. patent application Ser. No. 15/657,390, filed on Jul. 24, 2017, now U.S. Pat. No. 10,201,226, issued on Feb. 12, 2019, 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

The present disclosure relates to a system and method for constructing an article, and more particularly to articles having a folded construct.

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.
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.
While known furniture and known furniture manufacturing methods have proven useful for their intended purposes, a need for continuous improvement in the pertinent art remains.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
One aspect of the disclosure provides a drawer assembly. The drawer assembly may include a bottom, a first side extending from the bottom, and a second side extending from the bottom opposite the first side. The second side may include a first wall portion and a second wall portion opposite the first wall portion. The first wall portion may be spaced apart from the second wall portion to define a first cavity therebetween. The first wall portion may include a first aperture in fluid communication with the first cavity.
This aspect may include one or more of the following optional features. In some implementations, the drawer assembly includes a third side extending between the first side and the second side.
In some implementations, a front component is detachably connected to the third side.
In some implementations, the first wall portion includes a second aperture spaced apart and linearly aligned with the first aperture. The second aperture may be in communication with the first cavity.
In some implementations, a first component is detachably connected to the second side.
In some implementations, portions of the first component are disposed through the first and the second apertures.
In some implementations, the first component is a drawer track.
In some implementations, the front component includes a first portion having a first and a second end, and a second portion spaced apart and opposing the first portion.
In some implementations, the second portion of the front component extends from the first end of the first portion in a direction towards the second end of the first portion. The second portion may terminate before the second end of the first portion.
In some implementations, the front component includes a second cavity disposed between the first portion and the second portion. A portion of the third side of the drawer assembly may be disposed within the second cavity.
In some implementations, the second portion of the front component includes a first and a second cutout. A portion of the first side of the drawer assembly may be disposed within the first cutout. A portion of the second side of the drawer assembly may be disposed within the second cutout.
In some implementations, the front component includes a third and a fourth aperture. The third side of the drawer assembly may include a fifth and a sixth aperture. The third aperture may be aligned with the fifth aperture. The fourth aperture may be aligned with the sixth aperture.
In some implementations, a handle is detachably coupled to the front component. A portion of the handle may be disposed within the third, fourth, fifth, and sixth apertures.
Another aspect of the disclosure provides a method of assembling a drawer assembly. The method includes folding a substrate at a first channel to form a first side. The method also includes folding the substrate at a second channel to form a second side. The method further includes folding the substrate at a third channel, a fourth channel, and a fifth channel to form a third side having a first cavity. The method also includes folding the substrate at a sixth channel, a seventh channel, and an eighth channel to form a fourth side having a second cavity.
This aspect may include one or more of the following optional features. In some implementations, the method further includes applying an adhesive to at least one of the first channel, the second channel, the third channel, the fourth channel, the fifth channel, the sixth channel, the seventh channel, and the eighth channel prior to folding.
In some implementations, the third side of the substrate includes a first aperture in communication with the first cavity. The fourth side of the substrate may include a second aperture in communication with the second cavity.
In some implementations, the method further includes detachably connecting a first component to an outer surface of the third side of the substrate, and detachably connecting a second component to an outer surface of the fourth side of the substrate.
In some implementations, a portion of the first component is disposed through the first aperture of the third side of the substrate. A portion of the second component may be disposed through the second aperture of the fourth side of the substrate.
In some implementations, the first and the second components are drawer tracks.
In some implementations, the method further includes detachably connecting a front component to the first side of the substrate. The front component may be configured to cover the first side of the substrate.
In some implementations, the front component includes a third cavity. The first side of the substrate may be disposed within the third cavity.
In some implementations, the front component includes a first and a second cutout. The third side of the substrate may be disposed within the first cutout and the fourth side of the substrate may be disposed within the second cutout.
In some implementations, the front component includes a first aperture. The first side of the substrate may include a second aperture. The first aperture may be aligned with the second aperture.
In some implementations, the method further includes detachably connecting a handle to the front component of the drawer assembly. A portion of the handle may be disposed within the first aperture of the front component and the second aperture of the first side of the substrate.
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

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a furniture unit in accordance with the principles of the present disclosure;

FIG. 2 is an exploded view of the furniture unit of FIG. 1;

FIG. 3 is a top view of the furniture unit of FIG. 1;

FIG. 4A is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 4B is an exploded view of the shelf of FIG. 4A;

FIG. 5 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 6 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 7A is a top view of a substrate prior to forming a shelf for use with the furniture unit of FIG. 1;

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;

FIG. 7C is a top view of a substrate prior to forming a ceiling baffle;

FIG. 7D is a perspective view of a ceiling baffle formed with the substrate of FIG. 7C;

FIG. 8 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 9 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 10 is an end view of a bedrail in accordance with the principles of the present disclosure;

FIG. 11 is an end view of another bedrail in accordance with the principles of the present disclosure;

FIG. 12 is an end view of another bedrail in accordance with the principles of the present disclosure;

FIG. 13A is a perspective view of a bedrail assembly in a partially assembled state in accordance with the principles of the present disclosure;

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;

FIG. 14A is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14B is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14C is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14D is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 15 is a perspective view of a drawer assembly in accordance with the principles of the present disclosure;

FIG. 16A is a top view of a substrate prior to forming a box component of the drawer assembly of FIG. 15;

FIG. 16B is a bottom view of the substrate of FIG. 16A prior to forming the box component of the drawer assembly of FIG. 15;

FIG. 16C is a perspective view of the box component of the drawer assembly of FIG. 15 during a method of manufacturing;

FIG. 17A is a perspective view of a front component of the drawer assembly of FIG. 15;

FIG. 17B is a top view of a substrate prior to forming the front component of FIG. 17A;

FIG. 18A is a cross-sectional view of the drawer assembly of FIG. 15 taken along line 18A-18A of FIG. 15.

FIG. 18B is a cross-sectional view of the drawer assembly of FIG. 15 taken along line 18B-18B of FIG. 15.

FIG. 18C is a cross-sectional view of the drawer assembly of FIG. 15 taken along line 18C-18C of FIG. 15; and

FIG. 19 is a side view of the drawer assembly of FIG. 15.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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 (+1-5 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.
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.
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.
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 α therebetween. The angle α may be between about fifteen degrees and about one hundred sixty-five degrees. As illustrated in FIG. 14A, in some implementations, the angle α is substantially equal to ninety degrees.
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.
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 θ therebetween. The angle θ 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 θ is substantially equal to ninety degrees.
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 β 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 β relative to the lower surface 90. The angle β 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 θ may be substantially equal to ninety degrees. If the hollow support portion 214 defines a triangle the angle β may be greater than ninety degrees. In some implementations, if the hollow support portion 214 defines a triangle, the angle (3 may be substantially equal to one hundred twenty degrees.
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.
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.
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.
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.
With reference to FIG. 5, another shelf 18 a for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 a 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.
The shelf 18 a may include the hollow proximal support 214 and a hollow distal support 216 a. As illustrated in FIG. 5, the hollow proximal support 214 and the hollow distal support 216 a may be disposed on opposite sides of the shelf 18 a. 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 216 a may include folding the distal portion 62 in a counterclockwise direction.
With reference to FIG. 6, another shelf 18 b for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 b 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.
The shelf 18 b may include a hollow support 216 b 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 216 b 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.
With reference to FIGS. 7A and 7B, another shelf 18 c (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 18 c may be substantially similar to that of the shelf 18 b, 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.
The substrate 46 of the shelf 18 c may include the hollow support 216 b 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 18 c 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 18 c 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 18 c may be utilized as a ceiling panel or baffle.
In other implementations, the shelf 18 c 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 18 c 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 18 c′ (FIG. 7D), formed from the substrate 46, is shown. The structure, function, and method of manufacturing the ceiling baffle 18 c′ may be substantially similar to that of the shelf 18 c, apart from any exceptions described below and/or shown in the Figures. In this regard, the substrate 46 may define a ceiling baffle 18 c′ having an opening 229 into the hollow support 216 c′.
With reference to FIG. 8, another shelf 18 d for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 d 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.
The shelf 18 d may include a support 216 d 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 216 d 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
With reference to FIG. 9, another shelf 18 e for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 e may be substantially similar to that of the shelves 18 and 18 b, 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 18 e is generally shown and described herein as being a “shelf 18 e,” it will be appreciated that article 18 e may be utilized in various ways within the scope of the present disclosure. For example, shelf 18 e may be utilized as a “shelf” for a bed. In this regard, the shelf 18 e may be utilized, and referred to herein, as a bedrail.
The shelf 18 e is a variation of the shelves 18 and 18 b shown in FIGS. 4 and 6, including a hollow proximal support 214 e and the hollow distal support 216 b, and excluding lower laminate layer 52. In particular, the shelf 18 e may include the hollow support 216 b 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 214 e by folding the proximal portion 60 in a counterclockwise direction, and forming the hollow distal support 216 b 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 18 e 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.
With reference to FIG. 10, a bedrail 18 f is shown. The structure, function, and method of manufacturing the bedrail 18 f may be substantially similar to that of the shelves 18, 18 b, 18 e, 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 18 f is generally shown and described herein as being a “bedrail 18 f,” it will be appreciated that article 18 f may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 f may be utilized as a “shelf” for use with the furniture unit 10.
The bedrail 18 f is a variation of the shelf 18 e shown in FIG. 9, including a hollow proximal support 214 f and a hollow distal support 216 f. In some implementations, the bedrail 18 f, like the shelf 18 e, excludes the lower laminate layer 52. In other implementations, the bedrail 18 f, like the shelf 18, includes the lower laminate layer 52. In particular, the bedrail 18 f may include the hollow support 216 f 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 214 f by folding the proximal portion 60 in a counterclockwise direction, and forming the hollow distal support 216 f 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 104-3 f and from the third seam 104-3 f to the proximal peripheral surfaces 64, 80, and the second portion 234 may extend from the second seam 104-2 to a fourth seam 104-4 f and from the fourth seam 104-4 f to the distal peripheral surfaces 66, 82. In particular, the first portion 232 may extend in the first direction from the third seam 104-3 f to the proximal peripheral surfaces 64, 80, and the second portion 234 may extend in the opposite second direction from the fourth seam 104-4 f 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. 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.
As previously described, the substrate 46 of the bedrail 18 f 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.
With reference to FIG. 11, a bedrail 18 g is shown. The structure, function, and method of manufacturing the bedrail 18 g may be substantially similar to that of the bedrail 18 f 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 18 g is generally shown and described herein as being a “bedrail 18 g,” it will be appreciated that article 18 g may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 g may be utilized as a “shelf” for use with the furniture unit 10.
The bedrail 18 g is a variation of the bedrail 18 f shown in FIG. 10, including the hollow distal support 216 f. In some implementations, the bedrail 18 g, like the bedrail 18 f, excludes the lower laminate layer 52. In other implementations, the bedrail 18 g, like the bedrail 18 f, includes the lower laminate layer 52. In particular, the bedrail 18 g may include the hollow support 216 f 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 216 f 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.
As previously described, the substrate 46 of the bedrail 18 g 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.
With reference to FIG. 12, a bedrail 18 h is shown. The structure, function, and method of manufacturing the bedrail 18 h may be substantially similar to that of the bedrail 18 f 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 18 h is generally shown and described herein as being a “bedrail 18 h” it will be appreciated that article 18 h may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 h may be utilized as a “shelf” for use with the furniture unit 10.
The bedrail 18 h is a variation of the bedrail 18 f shown in FIG. 10, including the hollow proximal support 214 f and a hollow distal support 216 h. In some implementations, the bedrail 18 h, like the bedrail 18 f, excludes the lower laminate layer 52. In other implementations, the bedrail 18 h, like the bedrail 18 f, includes the lower laminate layer 52. In particular, the bedrail 18 f may include the hollow support 216 h 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 216 h 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.
In some implementations, the bedrail 18 h includes a plurality of seams 104-3 h, 104-4 h, . . . 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 18 h may include three seams 104-nh. It will be appreciated, however, that the bedrail 18 h may include more or less than three seams 104-nh within the scope of the present disclosure. In forming the hollow distal support 216 h 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 104-3 n. 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 104-3 h, 104-4 h, . . . 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 104-3 n, 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).
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.
The bedrail assembly 300 may include a splice member 302 and one or more of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or one or more of the bedrails 18 f, 18 g, 18 h. In this regard, while the bedrail assembly 300 is generally shown and described as including two of the bedrails 18 f, it will be appreciated that the bedrails 18 f of the bedrail assembly 300 may be replaced with one or more of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or one or more of the bedrails 18 f, 18 g, 18 h 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.
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, 18 a, 18 b, 18 c, 18 d, 18 e or the bedrails 18 f, 18 g, 18 h. 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 216 f of the bedrail 18 f. 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.
Assembling the bedrail assembly 300 may include placing the splice member 302 within the hollow distal support 216 f of two bedrails 18 f (e.g., FIG. 13A) and moving a first of the bedrails 18 f toward the second of the bedrails 18 f. For example, assembling the bedrail assembly 300 may include moving a first of the bedrails 18 f toward the second of the bedrails 18 f until an end 26 h of the first of the bedrails 18 f abuts an end 28 h of the second of the bedrails 18 f. 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 18 f and the bedrail assembly 300.
With reference to FIG. 15, a drawer assembly 18 i is shown. The structure, function, and method of manufacturing the drawer assembly 18 i may be substantially similar to that of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or bedrails 18 f, 18 g, 18 h. 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., “i”) are used to identify those features that have been modified. While article 18 i is generally shown and described herein as being a “drawer assembly 18 i,” it will be appreciated that article 18 i may be utilized in various ways within the scope of the present disclosure. For example, the drawer assembly 18 i may be utilized as a “shelf” for use with the furniture unit 10.
As illustrated in FIG. 15, in some implementations, the drawer assembly 18 i may include a front component 290, a box component 292, and drawer tracks 282. The box component 292 may include a first side 280-1, a second side 280-2, a third side 280-3, a fourth side 280-4, and a bottom 280-5. The first side 280-1 may be spaced apart from and opposing the second side 280-2. The third side 280-3 may be spaced apart from and opposing the fourth side 280-4. The bottom 280-5 may extend from and between each of the first, second, third, and fourth sides 280-1, 280-2, 280-3, 280-4. In some implementations, the third side 280-3 may include, or otherwise define, a first cavity 286-1. The fourth side 280-4 may include, or otherwise define, a second cavity 286-2. While the first and second cavities 286-1, 286-2 are generally illustrated as defining rectangular (e.g., square) shapes, it will be appreciated that the first and second cavities 286-1, 286-2 may each define another shape such as a triangle, a circle, or another polygon within the scope of the present disclosure. It will be appreciated that the drawer assembly 18 i may include more or less than two cavities within the scope of the present disclosure.
With reference to FIGS. 16A-16C, the drawer assembly 18 i (e.g., the box component 292) may include, or otherwise be formed from, a substrate 46 i having a layered construct. In this regard, the substrate 46 i may include the base layer 48, the upper laminate layer 50, and the lower laminate layer 52. In some implementations, the substrate 46 i may be formed without the lower laminate layer 52.
As illustrated in FIG. 16A, the substrate 46 i may include a plurality of portions 310-1, 310-2, . . . 310-n. In some implementations, the substrate 46 i may include thirteen portions 310-1 to 310-13. It will be appreciated that the substrate 46 i may include more or less than thirteen portions 310-n within the scope of the present disclosure.
With further reference to FIG. 16A, in some examples, each of the plurality of portions 310-1 to 310-n may include a corresponding upper surface 74-1, 74-2, . . . 74-n and a corresponding lower surface 90-1, 90-2, . . . 90-n disposed on the opposite side of the substrate 46 i than the upper surface 74-1, 74-2, . . . 74-n. In some implementations, each of the plurality of portions 310-1, 310-2, . . . 310-n may further include a corresponding first end 312-1, 312-2, . . . 312-n, a corresponding second end 314-1, 314-2, . . . 314-n spaced apart from the first end 312-1, 312-2, . . . 312-n, a corresponding first side 316-1, 316-2, . . . 316-n, and a corresponding second side 318-1, 318-2, . . . 318-n spaced apart from the first side 316-1, 316-2, . . . 316-n. The substrate 46 i may define a thickness T extending between an upper surface (e.g., upper surface 74-n) and a lower surface (e.g., lower surface 90-n). The thickness T may be between two millimeters and ten millimeters. In some implementations, the thickness may be substantially equal to five millimeters.
In some implementations, the substrate 46 i may include a plurality of the seams 104-1, 104-2, . . . 104-n. As illustrated in FIG. 16A, in some implementations, the substrate 46 i may include twelve seams 104-1 to 104-12. It will be appreciated that the drawer assembly 18 i may include more or less than twelve seams 104-n within the scope of the present disclosure. The seams 104-1 to 104-12 may extend through the lower surface 90-n of the substrate 46 i. In some configurations, the seams 104-1 to 104-12 may extend through the lower surface 90-n, the lower laminate layer 52, and a portion of the base layer 48 of the substrate 46 i.
In some implementations, a first seam 104-1 may be disposed between the eighth portion 310-8 and the sixth portion 310-6 of the substrate 46 i. The first seam 104-1 may extend from the first end 312-8, 312-6 to the second end 314-8, 314-6 of either the eighth portion 310-8 or the sixth portion 310-6 of the substrate 46 i. A second seam 104-2 may be disposed between the sixth portion 310-6 and the second portion 310-2 of the substrate 46 i. The second seam 104-2 may extend from the first end 312-6, 312-2 to the second end 314-6, 314-2 of either the sixth portion 310-6 or the second portion 310-2 of the substrate 46 i. A third seam 104-3 may be disposed between the second portion 310-2 and the first portion 310-1 of the substrate 46 i. The third seam 104-3 may extend from the first end 312-2, 312-1 to the second end 314-2, 314-1 of either the second portion 310-2 or the first portion 310-1 of the substrate 46 i.
In some configurations, a fourth seam 104-4 may be disposed between the first portion 310-1 and the fourth portion 310-4 of the substrate 46 i. The fourth seam 104-4 may extend from the first end 312-1, 312-4 to the second end 314-1, 314-4 of either the first portion 310-1 or the fourth portion 310-7 of the substrate 46 i. A fifth seam 104-5 may be disposed between the fourth portion 310-4 and the seventh portion 310-7 of the substrate 46 i. The fifth seam 104-5 may extend from the first end 312-4, 312-7 to the second end 314-4, 314-7 of either the fourth portion 310-4 or the seventh portion 310-7 of the substrate 46 i. A sixth seam 104-6 may be disposed between the seventh portion 310-7 and the ninth portion 310-9 of the substrate 46 i. The sixth seam 104-6 may extend from the first end 312-7, 312-9 to the second end 314-7, 314-9 of either the seventh portion 310-7 or the ninth portion 310-9 of the substrate 46 i.
In some examples, a seventh seam 104-7 may be disposed between the tenth portion 310-10 and the third portion 310-3 of the substrate 46 i. The seventh seam 104-7 may extend from the first end 312-10 to the second end 314-10 of the tenth portion 310-10 of the substrate 46 i. An eighth seam 104-8 may be disposed between the third portion 310-3 and the eleventh portion 310-11 of the substrate 46 i. The eighth seam 104-8 may extend from the first end 312-11 to the second end 314-11 of the eleventh portion 310-11 of the substrate 46 i. A ninth seam 104-9 may be disposed between the twelfth portion 310-12 and the fifth portion 310-5 of the substrate 46 i. The ninth seam 104-9 may extend from the first end 312-12 to the second end 314-12 of the twelfth portion 310-12 of the substrate 46 i.
In some implementations, a tenth seam 104-10 may be disposed between the fifth portion 310-5 and the thirteenth portion 310-13 of the substrate 46 i. The tenth seam 104-10 may extend from the first end 312-13 to the second end 314-13 of the thirteenth portion 310-13 of the substrate 46 i. An eleventh seam 104-11 may be disposed between the first portion 310-1 and the third portion 310-3 of the substrate 46 i. The eleventh seam 104-11 may extend from the first side 316-1, 316-3 to the second side 318-1, 318-3 of either the first portion 310-1 or the third portion 310-3 of the substrate 46 i. A twelfth seam 104-12 may be disposed between the first portion 310-1 and the fifth portion 310-5 of the substrate 46 i. The twelfth seam 104-12 may extend from the first side 316-1, 316-5 to the second side 318-1, 318-5 of either the first portion 310-1 or the fifth portion 310-5 of the substrate 46 i.
In some configurations, the seams 104-1 to 104-10 may extend substantially parallel (+/−5 degrees) to one another. The seams 104-1 to 104-10 may extend substantially orthogonal to the eleventh seam 104-11 and the twelfth seam 104-12. The eleventh seam 104-11 and the twelfth seam 104-12 may extend substantially parallel to one another.
With reference to FIGS. 16A-16C, a method a manufacturing the box component 292 may be substantially similar to the previously described method of manufacturing the component of shelf section 12-1, 12-2, . . . 12-n (i.e., shelf 18, lateral leg 20, medial leg 22, and backer 24). In this regard, the method of manufacturing the box component 292 may include providing the tool 200 (e.g., a router, a blade, a bit, etc.) and using the tool to form the plurality of primary channels 202 in the substrate 46 i, e.g, by miter cutting the plurality of primary channels 202 in the substrate 46 i. 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, as previously described relative to method of manufacturing the component of shelf section 12-1, 12-2, . . . 12-n (i.e., shelf 18, lateral leg 20, medial leg 22, and backer 24).
With reference to FIG. 16B, the method may further include forming a plurality of apertures 284-1, 284-2, . . . 284-n in the substrate 46 i. The apertures 284-1, 284-2, . . . 284-n may extend through the lower laminate layer 52, the base layer 48, and the upper laminate layer 50. As illustrated in FIG. 16B, the apertures 284-n may be disposed at various locations in the substrate 46 i. While some of the apertures 284-n (e.g., apertures 284-3) are generally illustrated as circular shapes, it will be appreciated that the apertures 284-n may each define another shape such as triangle, rectangle, oval, ellipse, or another polygon within the scope of the present disclosure. It will be appreciated that the drawer assembly 18 i may include more or less than two apertures within the scope of the present disclosure.
As illustrated in FIGS. 16A and 16B, the method may include forming at least one aperture 284-3 in each of the portions 310-2 through 310-5, and 310-8 through 310-13. As will be described in more detail below, in an assembled configuration, a first aperture 284-3 formed in the fourth portion 310-4 may be aligned with a first aperture 284-3 formed in the ninth portion 310-9 and with an aperture 284-3 formed in the eleventh portion 310-11.
In some implementations, in an assembled configuration, a component (e.g., screw, nail, pin, etc.) may be disposed within the foregoing apertures 284-3 formed in the fourth portion 310-4, the ninth portion 310-9 and the eleventh portion 310-11. In some examples, a pin may be disposed within the foregoing apertures 284-3 to aid in securing the fourth portion 310-4, the ninth portion 310-9 and the eleventh portion 310-11 together.
In some implementations, in an assembled configuration, a second aperture 284-3 formed in the fourth portion 310-4 may be aligned with a second aperture 284-3 formed in the ninth portion 310-9 and with an aperture 284-3 formed in the thirteenth portion 310-13. A component (e.g., screw, nail, pin, etc.) may be disposed within the foregoing apertures 284-3 formed in the fourth portion 310-4, the ninth portion 310-9 and the thirteenth portion 310-13. In some examples, a pin may be disposed within the foregoing apertures 284-3 to aid in securing the fourth portion 310-4, the ninth portion 310-9 and the thirteenth portion 310-13 together.
In some configurations, in an assembled configuration, a first aperture 284-3 formed in the second portion 310-2 may be aligned with a first aperture 284-3 formed in the eighth portion 310-8 and with an aperture 284-3 formed in the tenth portion 310-10. A component (e.g., screw, nail, pin, etc.) may be disposed within the foregoing apertures 284-3 formed in the second portion 310-2, the eighth portion 310-8 and the tenth portion 310-10. In some examples, a pin may be disposed within the foregoing apertures 284-3 to aid in securing the second portion 310-2, the eighth portion 310-8 and the tenth portion 310-10 together.
In some implementations, in an assembled configuration, a second aperture 284-3 formed in the second portion 310-2 may be aligned with a second aperture 284-3 formed in the eighth portion 310-8 and with an aperture 284-3 formed in the twelfth portion 310-12. A component (e.g., screw, nail, pin, etc.) may be disposed within the foregoing apertures 284-3 formed in the second portion 310-2, the eighth portion 310-8 and the twelfth portion 310-12. In some examples, a pin may be disposed within the foregoing apertures 284-3 to aid in securing the second portion 310-2, the eighth portion 310-8 and the twelfth portion 310-12 together.
The method may also include forming a pair of apertures 284-1, 284-2 in each of the portions 310-4, 310-2, such that in the assembled configuration, the third side 280-3 and the fourth side 280-4 each include first and second apertures 284-1, 284-2. The apertures 284-1, 284-2 of the third side 208-3 may be accessible on an outer surface 328 of the third side 280-3 and may be in communication with the first cavity 286-1. The apertures 284-1, 284-2 of the fourth side 208-4 may be accessible on an outer surface 328 of the fourth side 280-4 and may be in communication with the second cavity 286-2. The apertures 284-1, 284-2 of the third and the fourth sides 280-3, 280-4 may include an elongate shape. In this regard, as illustrated in FIG. 16B, the first aperture 284-1 may have a major axis A1 extending in a first direction and the second aperture 284-2 may have a major axis A2 extending in a second direction. The second direction may be transverse (e.g., perpendicular) to the first direction. In some implementations, the first and the second apertures 284-1, 284-2 may include a first portion and a second portion. The first portion may be larger than the second portion. In particular, the first portion of the apertures 284-1, 284-2 may cover a larger area than that of the second portion of the apertures 284-1, 284-2. In some examples, the first portion of the apertures 284-1, 284-2 may include a substantially circular shape and the second portion of the apertures 284-1, 284-2 may include a substantially elongate shape.
With continued reference to FIG. 16B, the method may also include folding the substrate 46 i such that each first channel wall 204 of the primary channel 202 engages the second channel wall 206 of the same primary channel 202 to define a corresponding seam 104-n and fold 106-n. 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 i-1, 106 i-2, . . . 106 i-n may define, or otherwise as, a hinge for folding the substrate 46 i. Accordingly, each fold 106 i-1, 106 i-2, . . . 106 i-n may be referred to herein as a hinge 106 i-1, 106 i-2, . . . 106 i-n.
In some implementations, prior to conducting the folding operations, an adhesive 322 (e.g., a glue) may be applied in at least one of the primary channels 202. In some implementations, the adhesive 322 may be applied in all of the primary channels 202.
As illustrated in FIG. 16C, in some implementations, the folding operations, and the plurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds 106 i-1, 106 i-2, . . . 106 i-n defined thereby, form the first side 280-1, the second side 280-2, the third side 280-3, the fourth side 280-4, the first cavity 286-1 and the second cavity 286-2 of the box component 292 of the drawer assembly 18 i.
With reference to FIGS. 16A and 16C, in some implementations, the first side 280-1 of the box component 292 may be formed when the third portion 310-3 of the substrate 46 i is folded along the eleventh fold 106 i-11 to engage the first portion 310-1 of the substrate 46 i. The second side 280-2 of the box component 292 may be formed when the fifth portion 310-5 of the substrate 46 i is folded along the twelfth fold 106 i-12 to engage the first portion 310-1 of the substrate 46 i.
In some examples, the tenth portion 310-10 of the substrate 46 i may be folded along the seventh fold 106 i-7 to engage the third portion 310-3 of the substrate 46 i, the eleventh portion 310-11 of the substrate 46 i may be folded along the eighth fold 106 i-8 to engage the third portion 310-3 of the substrate 46 i, the twelfth portion 310-12 of the substrate 46 i may be folded along the ninth fold 106 i-9 to engage the fifth portion 310-5 of the substrate 46 i, and the thirteenth portion 310-13 of the substrate 46 i may be folded along the tenth fold 106 i-10 to engage the fifth portion 310-5 of the substrate 46 i.
In some implementations, at least one of upper surface 74-10 or the lower surface 90-10 of the tenth portion 310-10 of the substrate 46 i may include an adhesive (e.g., glue, two-sided tape, etc.), and at least one of upper surface 74-11 or the lower surface 90-11 of the eleventh portion 310-11 of the substrate 46 i may include an adhesive. In some examples, at least one of upper surface 74-12 or the lower surface 90-12 of the twelfth portion 310-12 of the substrate 46 i may include an adhesive, and at least one of upper surface 74-13 or the lower surface 90-13 of the thirteenth portion 310-13 of the substrate 46 i may include an adhesive.
In some implementations, the third side 280-3 of the box component 292 may be formed when (i) the fourth portion 310-4 of the substrate 46 i is folded along the fourth fold 106 i-4 to engage the first portion 310-1 of the substrate 46 i, (ii) the seventh portion 310-7 of the substrate 46 i is folded along the fifth fold 106 i-5 to engage the fourth portion 310-4 of the substrate 46 i, and (iii) the ninth portion 310-9 of the substrate is folded along the sixth fold 106 i-6 to engage the seventh portion 310-7 of the substrate 46 i and the first portion 310-1 of the substrate 46 i. In particular, (i) the lower surface 90-4 of the fourth portion 310-4 may engage the upper surfaces 74-11, 74-13 of the eleventh and thirteen portions 310-11, 310-13, (ii) the lower surface 90-9 of the ninth portion 310-9 may engage the lower surfaces 90-11, 90-13 of the eleventh and thirteen portions 310-11, 310-13, and (iii) the first side 316-9 of the ninth portion 310-9 of the substrate 46 i may engage the lower surface 90-1 of the first portion 310-1. In some examples, upon completion of the foregoing folding operations, the fourth portion 310-4 of substrate 46 i is spaced apart from the ninth portion 310-9 of the substrate 46 i thereby forming a first cavity 286-1 between the fourth and the ninth portions 310-4, 310-9.
In an assembled configuration, the eleventh portion 310-11 of the substrate 46 i may be disposed within the first cavity 286-1, thereby aligning the first apertures 284-3 formed in the fourth and the ninth portions 310-4, 310-9 with the aperture 284-3 formed in the eleventh portion 310-11. The thirteenth portion 310-13 of the substrate 46 i may be disposed within the first cavity 286-1, thereby aligning the second apertures 284-3 formed in the fourth and the ninth portions 310-4, 310-9 with the aperture 284-3 formed in the thirteenth portion 310-13.
As illustrated in FIGS. 16A and 16B, in some implementations, the ninth portion 310-9 of the substrate 46 i may include at least one tab portion 324 extending from the first side 316-9 of the ninth portion 310-9. Upon the completion of the foregoing folding operations, each tab portion 324 of the ninth portion 310-9 may be disposed within a corresponding recess 326 formed in the lower surface 90-1 of the first portion 310-1 to secure the box component 292 in the folded configuration. In some examples, the recess 326 may have a substantially similar shape as the tab portion 324.
With reference to FIGS. 16A and 16C, in some implementations, the fourth side 280-4 of the box component 292 may be formed when (i) the second portion 310-2 of the substrate 46 i is folded along the third fold 106 i-3 to engage the first portion 310-1 of the substrate 46 i, (ii) the sixth portion 310-6 of the substrate 46 i is folded along the second fold 106 i-2 to engage the second portion 310-2 of the substrate 46 i, and (iii) the eighth portion 310-8 of the substrate is folded along the first fold 106 i-1 to engage the sixth portion 310-6 of the substrate 46 i and the first portion 310-1 of the substrate 46 i. In particular, (i) the lower surface 90-2 of the second portion 310-2 may engage the upper surfaces 74-10, 74-12 of the tenth and twelfth portions 310-10, 310-12, (ii) the lower surface 90-8 of the eighth portion 310-8 may engage the lower surfaces 90-10, 90-12 of the tenth and twelfth portions 310-10, 310-12, and (iii) the second side 318-8 of the eighth portion 310-8 of substrate 46 i may engage the lower surface 90-1 of the first portion 310-1. In some examples, upon completion of the foregoing folding operations, the second portion 310-2 of substrate 46 i is spaced apart from the eighth portion 310-8 of the substrate 46 i thereby forming a second cavity 286-2 between the second and eighth portions 310-2, 310-8.
In an assembled configuration, the tenth portion 310-10 of the substrate 46 i may be disposed within the second cavity 286-2, thereby aligning the first apertures 284-3 formed in the second and the eighth portions 310-2, 310-8 with the aperture 284-3 formed in the tenth portion 310-10. The twelfth portion 310-12 of the substrate 46 i may be disposed within the second cavity 286-2, thereby aligning the second apertures 284-3 formed in the second and the eighth portions 310-2, 310-8 with the aperture 284-3 formed in the twelfth portion 310-12.
As illustrated in FIGS. 16A and 16B, in some implementations, the eighth portion 310-8 of the substrate 46 i may include at least one tab portion 324 extending from the second side 318-8 of the eighth portion 310-8. Upon the completion of the foregoing folding operations, each tab portion 324 of the eighth portion 310-8 may be disposed within a corresponding recess 326 formed in the lower surface 90-1 of the first portion 310-1 to secure the box component 292 in the folded configuration. In some examples, the recess 326 may have a substantially similar shape as the tab portion 324.
With reference to FIGS. 18A, 18B and 19, in some implementations, a component (e.g., a drawer track, bracket, etc.) may be detachably coupled to the third side 280-3 of the box component 292. In some implementations, a first drawer track 282-1 may include at least one peg 283. In some examples, a first peg 283-1 of the first drawer track 282-1 may be disposed within the first aperture 284-1 of the third side 280-3 and at least partially within the first cavity 286-1, while a second peg 283-2 of the first drawer track 282-1 may be disposed within the second aperture 284-2 of the third side 280-3 and at least partially within the first cavity 286-1, thereby securing the first drawer track 282-2 to the box component 292.
In some implementations, a method of securing the first drawer track 282-1 to the box component 292 may include positioning the second peg 283-2 of the first drawer track 282-1 within the first portion of the second aperture 284-2. The method may subsequently include moving the second peg 283-2 along the axis A2 from the first portion of the second aperture 284-2 to the second portion of the second aperture 284-2, thereby securing the second peg 283-2 within the first cavity 286-1. In some implementations, the method of securing the first drawer track 282-1 to the box component 292 may also include positioning the first peg 283-1 of the first drawer track 282-1 within the first portion of the first aperture 284-1, and moving the first peg 283-1 along the axis A1 to the second portion of the first aperture 284-1, thereby securing the first peg 283-1 within the first cavity 286-1.
With continued reference to FIGS. 18A, 18B and 19, in some implementations, a component (e.g., a drawer track, bracket, etc.) may be detachably coupled to the fourth side 280-4 of the box component 292. In some implementations, a second drawer track 282-2 may include at least one peg 283. In some examples, a first peg 283-1 of the second drawer track 282-2 may be disposed within the first aperture 284-1 of the fourth side 280-4 and at least partially within the second cavity 286-2, while a second peg 283-2 of the second drawer track 282-2 may be disposed within the second aperture 284-2 of the fourth side 280-4 and at least partially within the second cavity 286-2, thereby securing the second drawer track 282-2 to the box component 292.
In some implementations, a method of securing the second drawer track 282-2 to the box component 292 may include positioning the second peg 283-2 of the second drawer track 282-2 within the first portion of the second aperture 284-2. The method may subsequently include moving the second peg 283-2 along the axis A1 from the first portion of the second aperture 284-2 to the second portion of the second aperture 284-2, thereby securing the second peg 283-2 within the second cavity 286-2. In some implementations, the method of securing the second drawer track 282-2 to the box component 292 may also include positioning the first peg 283-1 of the second drawer track 282-2 within the first portion of the first aperture 284-1, and moving the first peg 283-1 along the axis A1 to the second portion of the first aperture 284-1, thereby securing the first peg 283-1 within the second cavity 286-2.
With reference to FIG. 15, in some implementations, the drawer assembly 18 i may include a front component 290 detachably connected to and configured to cover at least a portion of the first side 280-1 of the box component 292. The method of manufacturing the front component 290 may be substantially similar to that of the drawer assembly 18 i. Accordingly, the structure and or function of similar features will not be described again detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extension (i.e., “j”) are used to identify those features that have been modified.
As illustrated in FIG. 17A, the front component 290 may include a cavity 286, a first cutout 296-1, a second cutout 296-2, and at least one aperture 294. With reference to FIG. 15, a portion of the first side 280-1 of the box component 292 may be disposed within the cavity 286 of the front component 290, a portion of the fourth side 280-4 of the box component 292 may be disposed within the first cutout 296-1, and a portion of the third side 280-3 of the box component 292 may be disposed within the second cutout 296-2. In some examples, the front component 290 may include first and second apertures 294-1, 294-2 which may be aligned with apertures 284 within the first side 280-1 of the box component 292. In some implementations, a component (e.g., a handle, knob, etc.) may be detachably coupled to the front component 290. In particular, a portion of a handle 288 may be disposed within the first and second apertures 291-1, 291-2 of the front component 290, and the apertures 284 of the first side 280-1 of the box component 292.
With reference to FIGS. 17A and 17B, the front component 290 may include, or otherwise be formed from, a substrate 46 j having a layered construct. In this regard, the substrate 46 j may include a base layer 48, an upper laminate layer 50, and a lower laminate layer 52. As illustrated in FIG. 17B, the substrate 46 j may include a plurality of portions 310 j-1, 310 j-2, . . . 310 j-n. In some implementations, the substrate 46 j may include six portions 310 j-1 to 310 j-6. It will be appreciated that the substrate 46 j may include more or less than six portions 310 j-n within the scope of the present disclosure.
In some implementations, the front component 290 may include a plurality of seams 104-1, 104-2, . . . 104-n. As illustrated in FIG. 17B, in some implementations, the front component 290 may include five seams 104-1 to 104-5. It will be appreciated that the front component 290 may include more or less than five seams 104-n within the scope of the present disclosure. The seams 104-1 to 104-5 may extend through the upper surface 50 of the substrate 46 i. In some configurations, the seams 104-1 to 104-5 may extend through the upper surface 50 and the base layer 48 of the substrate 46 i.
With reference to FIGS. 17A and 17B, the front component 290 may be formed by performing a plurality of folding operations to define the plurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds 106 j-1, 106 j-2, . . . 106 j-n may define, or otherwise as, a hinge for folding the substrate 46 j. Accordingly, each fold 106 j-1, 106 j-2, . . . 106 j-n may be referred to herein as a hinge 106 j-1, 106 j-2, . . . 106 j-n. In some implementations, the front component 290 may be formed by folding the second portion 310 j-2 of the substrate 46 j along the fourth fold 106 j-4 to engage the first portion 310 j-1, folding the third portion 310 j-3 along the first fold 106 j-1 to engage the first portion 310 j-1, folding the fourth portion 310 j-4 along the second fold 106 j-2 to engage the first portion 310 j-1, folding the fifth portion 310 j-5 along the third fold 106 j-3 to engage the first portion 310 j-1, and folding the sixth portion 310 j-6 along the fifth fold 106 j-5 to engage the third portion 310 j-3.
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, 18 a, 18 b, 18 c, 18 d, 18 e, the bedrails 18 f, 18 g, 18 h, the drawer assembly 18 i, the furniture unit 10, and the bedrail assembly 300 to have superior strength and durability.
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.

Claims

What is claimed is:

1. A drawer assembly comprising:

a bottom;

a first side extending from the bottom;

a second side extending from the bottom opposite the first side, the second side including a first wall portion and a second wall portion opposite the first wall portion, the first wall portion spaced apart from the second wall portion to define a first cavity therebetween, the first wall portion including a first aperture in fluid communication with the first cavity;

2. The drawer assembly of claim 1, further comprising a third side extending between the first side and the second side.

3. The drawer assembly of claim 2, further comprising a front component detachably connected to the third side.

4. The drawer assembly of claim 1, wherein the first wall portion includes a second aperture spaced apart and linearly aligned with the first aperture, the second aperture in communication with the first cavity.

5. The drawer assembly of claim 4, wherein a first component is detachably connected to the second side.

6. The drawer assembly of claim 5, wherein portions of the first component are disposed through the first and the second apertures.

7. The drawer assembly of claim 6, wherein the first component is a drawer track.

8. The drawer assembly of claim 3, wherein the front component includes a first portion having a first and a second end and a second portion spaced apart and opposing the first portion.

9. The drawer assembly of claim 8, wherein the second portion of the front component extends from the first end of the first portion in a direction towards the second end of the first portion, the second portion terminating before the second end of the first portion.

10. The drawer assembly of claim 9, wherein the front component includes a second cavity disposed between the first portion and the second portion, and wherein a portion of the third side of the drawer assembly is disposed within the second cavity.

11. The drawer assembly of claim 10, wherein the second portion of the front component includes a first and a second cutout, wherein a portion of the first side of the drawer assembly is disposed within the first cutout, and wherein a portion of the second side of the drawer assembly is disposed within the second cutout.

12. The drawer assembly of claim 11, wherein the front component includes a third and a fourth aperture, wherein the third side of the drawer assembly includes a fifth and a sixth aperture, and wherein the third aperture is aligned with the fifth aperture and the fourth aperture is aligned with the sixth aperture.

13. The drawer assembly of claim 12, wherein a handle in detachably coupled to the front component, and wherein a portion of the handle is disposed within the third, fourth, fifth and sixth apertures.

14. A method of assembling a drawer assembly, the method comprising:

folding a substrate at a first channel to form a first side;

folding the substrate at a second channel to form a second side;

folding the substrate at a third channel, a fourth channel, and a fifth channel to form a third side having a first cavity; and

folding the substrate at a sixth channel, a seventh channel, and an eighth channel to form a fourth side having a second cavity.

15. The method of claim 14, further comprising applying an adhesive to at least one of the first channel, the second channel, the third channel, the fourth channel, the fifth channel, the sixth channel, the seven channel and the eighth channel prior to folding.

16. The method of claim 14, wherein the third side of the substrate includes a first aperture in communication with the first cavity and the fourth side of the substrate includes a second aperture in communication with the second cavity.

17. The method of claim 16, further comprising detachably connecting a first component to an outer surface of the third side of the substrate, and detachably connecting a second component to an outer surface of the fourth side of the substrate.

18. The method of claim 17, wherein a portion of the first component is disposed through the first aperture of the third side of the substrate, and a portion of the second component is disposed through the second aperture of the fourth side of the substrate.

19. The method of claim 18, wherein the first and the second components are drawer tracks.

20. The method of claim 14, further comprising detachably connecting a front component to the first side of the substrate, wherein the front component is configured to cover the first side of the substrate.

21. The method of claim 20, wherein the front component includes a third cavity, and wherein the first side of the substrate is disposed within the third cavity.

22. The method of claim 21, wherein the front component includes a first and a second cutout, wherein the third side of the substrate is disposed within the first cutout, and wherein the fourth side of the substrate is disposed within the second cutout.

23. The method of claim 22, wherein the front component includes a first aperture, wherein the first side of the substrate includes a second aperture, and wherein the first aperture is aligned with the second aperture.

24. The method of claim 23, further comprising detachably connecting a handle to the front component of the drawer assembly, wherein a portion of the handle is disposed within the first aperture of the front component and the second aperture of the first side of the substrate.