US20190254423A1 - System and method for flat packed furniture to enable reuse of packaging materials - Google Patents
System and method for flat packed furniture to enable reuse of packaging materials Download PDFInfo
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- US20190254423A1 US20190254423A1 US16/399,613 US201916399613A US2019254423A1 US 20190254423 A1 US20190254423 A1 US 20190254423A1 US 201916399613 A US201916399613 A US 201916399613A US 2019254423 A1 US2019254423 A1 US 2019254423A1
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- Prior art keywords
- piece
- fold
- cabinet
- furniture
- packaging
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- 238000000034 method Methods 0.000 title claims abstract description 35
- 239000005022 packaging material Substances 0.000 title description 2
- 238000004806 packaging method and process Methods 0.000 claims abstract description 146
- 238000012856 packing Methods 0.000 claims abstract description 34
- 238000012857 repacking Methods 0.000 claims abstract description 6
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000010276 construction Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 238000000429 assembly Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B47/00—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B96/00—Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
- A47B96/20—Furniture panels or like furniture elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/64—Containers, packaging elements or packages, specially adapted for particular articles or materials for bulky articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2585/00—Containers, packaging elements or packages specially adapted for particular articles or materials
- B65D2585/64—Containers, packaging elements or packages specially adapted for particular articles or materials for bulky articles
- B65D2585/641—Containers, packaging elements or packages specially adapted for particular articles or materials for bulky articles specific articles
- B65D2585/647—Containers, packaging elements or packages specially adapted for particular articles or materials for bulky articles specific articles furniture
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D77/00—Packages formed by enclosing articles or materials in preformed containers, e.g. boxes, cartons, sacks or bags
- B65D77/08—Materials, e.g. different materials, enclosed in separate compartments formed during filling of a single container
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
- B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
- B65D81/07—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using resilient suspension means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
- B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
- B65D81/127—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material
- B65D81/133—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material of a shape specially adapted to accommodate contents, e.g. trays
Definitions
- the present invention relates generally to the field of flat packed furniture, and more particularly to methods and systems for flat packing to reduce shipping cost.
- Flat packing of cabinets and furniture is generally done for the purpose of reducing logistics/transportation costs from the manufacturing/distribution source to the user/consumer.
- the packaging design has as a principal purpose of ensuring that the product can get to the desired location without damage.
- the packaging of many products is designed with the DIY consumer in mind and does not consider reuse of any of the packaging materials.
- a furniture product that is designed to be initially shipped as a flat packed product may require multiple flat pack boxes to make a specific assembled stock keeping unit (SKU).
- SKU stock keeping unit
- Generic sub-assemblies can be used across multiple SKUs and may be packed independently of sub-assemblies that are unique to a specific SKU. These types of products may be referred to as modular flat packed products.
- a growing market is emerging, particularly with more expensive materials/products, where the flat packed product is shipped to a reseller/dealer; the reseller/dealer assembles the product, repackages the product as an assembly and delivers it or arranges delivery to the consumer or the jobsite.
- the kitchen cabinet industry is an example where this trend is growing.
- a flat packed furniture system can include a plurality of boxes; wherein each box in the plurality of boxes comprises a packaging piece and a set of furniture parts, such that the set of furniture parts is flat packed inside the packaging piece; such that a plurality of parts in the plurality of boxes is configured to be assemblable as a furniture item; such that a plurality of packaging pieces in the plurality of boxes is configured to be reused as packaging for the furniture item.
- the plurality of boxes can further include:
- a method for flat packing furniture can include:
- FIG. 1 is a perspective view of a flat packed furniture system in an initial configuration for shipping, according to an embodiment of the invention.
- FIG. 2A is a left front perspective view of a furniture item assembled from the flat packed furniture system in an initial configuration for shipping, according to an embodiment of the invention.
- FIG. 2B is a right front perspective view of the furniture item shown in FIG. 2A .
- FIG. 2C is a right rear perspective view of the furniture item shown in FIG. 2A .
- FIG. 2D is a left bottom perspective view of the furniture item shown in FIG. 2A .
- FIG. 3A is a top elevation view of a first packaging piece of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 3B is a top elevation view of a second packaging piece of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 3C is a top elevation view of a third packaging piece of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 3D is a top elevation view of a fourth packaging piece of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 4A is a perspective view of a first set of furniture parts of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 4B is a perspective view of a second set of furniture parts of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 4C is a perspective view of a third set of furniture parts of the flat packed furniture system, according to an embodiment of the invention.
- FIG. 5A is a flowchart illustrating steps that may be followed, in accordance with one embodiment of a method or process of flat packing furniture.
- FIG. 5B is a flowchart illustrating a sequence of locations, in accordance with one embodiment of a method or process of flat packing furniture.
- FIG. 6A is a left front perspective view of a furniture item assembled from the flat packed furniture system in an initial configuration for shipping and packaged with reused packaging pieces, according to an embodiment of the invention.
- FIG. 6B is a right front perspective view of the furniture item packaged with reused packaging pieces shown in FIG. 6A .
- FIG. 6C is a right rear perspective view of the furniture item packaged with reused packaging pieces shown in FIG. 6A .
- FIG. 6D is a left bottom perspective view of the furniture item packaged with reused packaging pieces shown in FIG. 6A .
- the final shape of many of the flat packet products when assembled are rectangular with 6 planes—left and right, front and back, and top and bottom.
- the standard packaging is 1 box per assembly or if the product is modular, 1 box per group of modular components.
- the proposed invention is associated with the growing market requiring repacking of the modular flat packed product when it is assembled.
- a flat packed furniture system 100 which also can be referred to as a modular flat packed furniture system 100 , can comprise a plurality of boxes 110 120 130 , such that each box 110 120 130 contains packaging pieces and parts for a furniture item, such that the plurality of parts from each box 110 120 130 can be assembled as the furniture item, and such that the packaging pieces from each box 110 120 130 , can be reused as packaging for the furniture item.
- a flat packed furniture system 100 can include:
- the packaging pieces 112 122 132 334 can be flat pieces of cardboard, made of types of cardboard commonly used for boxes/packaging, but can also be made of other flat pieces made of materials suitable for packaging.
- the flat packed furniture system 100 can be configured such that the first, second, and third sets of furniture parts 410 420 430 are configured to be assemblable as a cabinet 200 , which can include B30 and W1830 cabinet sizes, and other cabinet sizes and designs, including standardized and proprietary sizes and design.
- the flat packed furniture system 100 can be configured such that:
- the flat packed furniture system 100 is a modular packaging system adapted for reuse of packaging, such that flat packed furniture system 100 optimizes for both reduced storage/inventory cost and reduced packaging cost, such that when a manufacturer produces a portfolio of cabinets, including a first plurality, n, of cabinet models, each cabinet model including a second plurality, c, of color options, then the manufacturer must produce:
- the flat packed furniture system 100 can be configured such that:
- the first packaging piece 112 can be configured for packaging reuse, such that the first packaging piece 112 can include attach/fold pieces connected by perforated borders, including
- the second packaging piece 122 can be configured for packaging reuse, such that the second packaging piece 122 can include attach/fold pieces connected by perforated borders, including
- the third packaging piece 132 can be configured for packaging reuse, such that the third packaging piece 132 can include attach/fold pieces connected by perforated borders, including
- the fourth packaging piece 334 can be configured for packaging reuse, such that the fourth packaging piece 334 can include attach/fold pieces connected by perforated borders, including
- FIGS. 6A, 6B, 6C, and 6D shows the first, second, third, and fourth packaging pieces 112 122 132 334 used for packaging reuse, such that the cabinet 200 is packaged with the first, second, third, and fourth packaging pieces 112 122 132 334 , to form a repackaged cabinet 600 .
- the perspective views of FIGS. 6A, 6B, 6C, and 6D correspond substantially to the views of FIGS. 6A, 6B, 6C, and 6D , respectively, with the first, second, third, and fourth packaging pieces 112 122 132 334 added.
- the first, second, third, and fourth packaging pieces 112 122 132 334 when used for packaging reuse to package the assembled cabinet 200 , the first, second, third, and fourth packaging pieces 112 122 132 334 can be secured using packaging tape, staples, and/or other packaging fasteners.
- FIGS. 6A, 6B, 6C, and 6D show a related embodiment, as shown in FIGS. 6A, 6B, 6C, and 6D :
- a method for flat packing furniture 500 can include:
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Packaging Of Machine Parts And Wound Products (AREA)
Abstract
A flat packed furniture system includes a plurality of boxes, each comprising a packaging piece and a set of furniture parts, such that the set of furniture parts is flat packed inside the packaging piece, such that a plurality of parts in the plurality of boxes is configured to be assemblable as a furniture item, which can be a cabinet, such that a plurality of packaging pieces in the plurality of boxes is configured to be reused as packaging for the furniture item. Also disclosed is a method for flat packing furniture, including flat packing, shipping, unpacking, assembling, repacking, and reshipping.
Description
- This application is a continuation of U.S. Non-Provisional application Ser. No. 15/584,924, filed May 2, 2017; which claims the benefit of U.S. Provisional Application No. 62/332,432, filed May 5, 2016; both of which are incorporated herein by reference in their entirety.
- The present invention relates generally to the field of flat packed furniture, and more particularly to methods and systems for flat packing to reduce shipping cost.
- Flat packing of cabinets and furniture is generally done for the purpose of reducing logistics/transportation costs from the manufacturing/distribution source to the user/consumer.
- The packaging design has as a principal purpose of ensuring that the product can get to the desired location without damage. The packaging of many products is designed with the DIY consumer in mind and does not consider reuse of any of the packaging materials.
- A furniture product that is designed to be initially shipped as a flat packed product may require multiple flat pack boxes to make a specific assembled stock keeping unit (SKU). Generic sub-assemblies can be used across multiple SKUs and may be packed independently of sub-assemblies that are unique to a specific SKU. These types of products may be referred to as modular flat packed products.
- A growing market is emerging, particularly with more expensive materials/products, where the flat packed product is shipped to a reseller/dealer; the reseller/dealer assembles the product, repackages the product as an assembly and delivers it or arranges delivery to the consumer or the jobsite. The kitchen cabinet industry is an example where this trend is growing.
- However, this process entails packaging the product twice, and since there is generally no reuse of materials, the manufacturer will consequently incur significant material and labor costs for repackaging.
- As such, considering the foregoing, it may be appreciated that there continues to be a need for novel and improved devices and methods for flat packing of cabinets and furniture with reduced logistics/transportation costs.
- The foregoing needs are met, to a great extent, by the present invention, wherein in aspects of this invention, enhancements are provided to the existing model of flat packing of cabinets and furniture.
- In an aspect, a flat packed furniture system can include a plurality of boxes; wherein each box in the plurality of boxes comprises a packaging piece and a set of furniture parts, such that the set of furniture parts is flat packed inside the packaging piece; such that a plurality of parts in the plurality of boxes is configured to be assemblable as a furniture item; such that a plurality of packaging pieces in the plurality of boxes is configured to be reused as packaging for the furniture item.
- In a related aspect, the plurality of boxes can further include:
-
- a) a first box, comprising:
- i. a first packaging piece; and
- ii. a first set of furniture parts, wherein the first set of furniture parts is packaged inside the first packaging piece;
- b) A second box, comprising:
- i. a second packaging piece; and
- ii. a second set of furniture parts, wherein the second set of furniture parts is packaged inside the second packaging piece;
- c) a third box, comprising:
- i. a third packaging piece;
- ii. a fourth packaging piece; and
- iii. a third set of furniture parts, wherein the third set of furniture parts is packaged inside the third and fourth packaging pieces;
- wherein the first, second, and third sets of furniture parts are configured to be assemblable as a furniture item;
- such that the packaging pieces are configured to be reused as packaging for the furniture item, such that the packaging pieces are configured to cover outer surfaces of the assembled furniture item.
- a) a first box, comprising:
- In an aspect, a method for flat packing furniture, can include:
-
- a) Flat packing a furniture item, wherein a plurality of parts for a furniture item are flat packaged inside a plurality of packaging pieces, producing a plurality of boxes;
- b) Shipping the flat packed furniture item, wherein the plurality of boxes is shipped from a manufacturing location to a reseller location;
- c) Unpacking the flat packed furniture item, wherein the plurality of parts is unpackaged from the plurality of boxes;
- d) Assembling the furniture item, wherein the furniture item is assembled from the plurality of parts;
- e) Re-packing the assembled furniture item, wherein the assembled furniture item is re-packaged with the plurality of packaging pieces; and
- f) Re-shipping the assembled furniture item, wherein the re-packaged furniture item is shipped from the reseller location to a customer location.
- There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
- In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
- As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
-
FIG. 1 is a perspective view of a flat packed furniture system in an initial configuration for shipping, according to an embodiment of the invention. -
FIG. 2A is a left front perspective view of a furniture item assembled from the flat packed furniture system in an initial configuration for shipping, according to an embodiment of the invention. -
FIG. 2B is a right front perspective view of the furniture item shown inFIG. 2A . -
FIG. 2C is a right rear perspective view of the furniture item shown inFIG. 2A . -
FIG. 2D is a left bottom perspective view of the furniture item shown inFIG. 2A . -
FIG. 3A is a top elevation view of a first packaging piece of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 3B is a top elevation view of a second packaging piece of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 3C is a top elevation view of a third packaging piece of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 3D is a top elevation view of a fourth packaging piece of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 4A is a perspective view of a first set of furniture parts of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 4B is a perspective view of a second set of furniture parts of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 4C is a perspective view of a third set of furniture parts of the flat packed furniture system, according to an embodiment of the invention. -
FIG. 5A is a flowchart illustrating steps that may be followed, in accordance with one embodiment of a method or process of flat packing furniture. -
FIG. 5B is a flowchart illustrating a sequence of locations, in accordance with one embodiment of a method or process of flat packing furniture. -
FIG. 6A is a left front perspective view of a furniture item assembled from the flat packed furniture system in an initial configuration for shipping and packaged with reused packaging pieces, according to an embodiment of the invention. -
FIG. 6B is a right front perspective view of the furniture item packaged with reused packaging pieces shown inFIG. 6A . -
FIG. 6C is a right rear perspective view of the furniture item packaged with reused packaging pieces shown inFIG. 6A . -
FIG. 6D is a left bottom perspective view of the furniture item packaged with reused packaging pieces shown inFIG. 6A . - Before describing the invention in detail, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will readily be apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and specification describe in greater detail other elements and steps pertinent to understanding the invention.
- The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive.
- The final shape of many of the flat packet products when assembled are rectangular with 6 planes—left and right, front and back, and top and bottom. The standard packaging is 1 box per assembly or if the product is modular, 1 box per group of modular components.
- The proposed invention is associated with the growing market requiring repacking of the modular flat packed product when it is assembled.
- In the following, we describe the structure of an embodiment of a flat packed
furniture system 100 with reference toFIG. 1 , in such manner that like reference numerals refer to like components throughout; a convention that we shall employ for the remainder of this specification. - In an embodiment a flat packed
furniture system 100, which also can be referred to as a modular flat packedfurniture system 100, can comprise a plurality ofboxes 110 120 130, such that eachbox 110 120 130 contains packaging pieces and parts for a furniture item, such that the plurality of parts from eachbox 110 120 130 can be assembled as the furniture item, and such that the packaging pieces from eachbox 110 120 130, can be reused as packaging for the furniture item. - In a related embodiment, as shown in
FIGS. 1, 2A-2D, 3A-3D, and 4A-4D , a flat packedfurniture system 100 can include: -
- a) A
first box 110, which can include:- i. A
first packaging piece 112, as shown inFIGS. 1 and 3A ; and - ii. A first set of
furniture parts 410, as shown inFIG. 4A , wherein the first set offurniture parts 410 is packaged inside thefirst packaging piece 112;
- i. A
- b) A
second box 120, which can include:- i. A
second packaging piece 122, as shown inFIGS. 1 and 3B ; and - ii. A second set of
furniture parts 420, as shown inFIG. 4B , wherein the second set offurniture parts 420 is packaged inside thesecond packaging piece 122;
- i. A
- c) A
third box 130, which can include:- i. a
third packaging piece 132, as shown inFIGS. 1 and 3C ; - ii. a
fourth packaging piece 334, as shown inFIG. 3D ; and - iii. A third set of
furniture parts 430, as shown inFIG. 4C , wherein the third set offurniture parts 430 is packaged inside the third andfourth packaging pieces 132 334; - such that the third and
fourth packaging pieces 132 334 are mounted on opposing sides, in a shoebox type configuration;
- i. a
- wherein the first, second, and third sets of
furniture parts 410 420 430 are configured to be assemblable as an assembledfurniture item 200; - such that the
packaging pieces 112 122 132 334 are configured to be reused as packaging for thefurniture item 200, such that thepackaging pieces 112 122 132 334 are configured to cover outer surfaces of the assembledfurniture item 200.
- a) A
- In related embodiments, the
packaging pieces 112 122 132 334 can be flat pieces of cardboard, made of types of cardboard commonly used for boxes/packaging, but can also be made of other flat pieces made of materials suitable for packaging. - In related embodiments, the flat packed
furniture system 100 can be configured such that the first, second, and third sets offurniture parts 410 420 430 are configured to be assemblable as acabinet 200, which can include B30 and W1830 cabinet sizes, and other cabinet sizes and designs, including standardized and proprietary sizes and design. - In a related embodiment, the flat packed
furniture system 100 can be configured such that: -
- a) the first set of
furniture parts 410 can include face parts of acabinet 200, including:- i. a
face panel 213, which is a part of afront side 203 of thecabinet 200; -
ii. doors 223, which are part of afront side 203 of thecabinet 200; - iii. a
back panel 206;
- i. a
- b) the second set of
furniture parts 420 can include gut parts of acabinet 200, including:- i. optionally, a
top panel 424; - ii. a
bottom panel 205; - iii. a
toe panel 208; - iv. parts for
drawer boxes 426; - v. corner blocks 422; and
- vi. brackets, screws and
other hardware 428;
- i. optionally, a
- c) the third set of
furniture parts 430 can include side parts of acabinet 200, including:- iv. a
right side 202; and - v. a
left side 201.
- iv. a
- a) the first set of
- In related embodiments, the flat packed
furniture system 100 is a modular packaging system adapted for reuse of packaging, such that flat packedfurniture system 100 optimizes for both reduced storage/inventory cost and reduced packaging cost, such that when a manufacturer produces a portfolio of cabinets, including a first plurality, n, of cabinet models, each cabinet model including a second plurality, c, of color options, then the manufacturer must produce: -
- a) n different first sets of
furniture parts 410, which are face parts, each in c different color options; - b) one second set of
furniture parts 420, which are gut parts that are generic (i.e. the same) for all combinations of cabinet models and colors; and - c) c different third sets of
furniture parts 430, which are side parts that are generic (i.e. the same) for all combinations of cabinet models, and only vary depending on the color option selection; - whereby when the manufacturer needs to produce/stock a new cabinet model, the manufacturer only needs to produce new versions of the
first box 110 with a first set offurniture parts 410, since both the second andthird boxes 120 130 with respectively second and third sets offurniture parts 420 430 are generic to the cabinet model version. Some high-end manufacturers package all parts in one large box, thereby maximizing storage/inventory cost and minimizing, and some mass market manufacturers will package a cabinet in a high number of boxes, such as for example nine boxes. The modular flat packedfurniture system 100, uses a novel approach of separating parts in face parts, gut parts, and side parts, in respectively the first, second, andthird boxes 110 120 130, and thereby optimizes for both minimal storage/inventory cost and for minimal packaging cost. The modular flat packedfurniture system 100 further reduces packaging cost by facilitating reuse of thepackaging pieces 112 122 132 334 of the first, second, andthird boxes 110 120 130 for packaging of an assembledcabinet 200, in preparation for further shipment when thecabinet 200 has been assembled from the face, gut, side parts of respectively the first, second, andthird boxes 110 120 130.
- a) n different first sets of
- In a related embodiment, wherein the
cabinet 200 is a B12 cabinet, the flat packedfurniture system 100 can be configured such that: -
- a) the
first box 110 can be 12″ wide, 30″ tall, and 2″ deep; - b) the
second box 120 can be 12″ wide, 24″ tall, and 3″ deep; - c) the
third box 130 can be 24″ wide, 34½″ tall, and 1″ deep.
- a) the
- In a related embodiment, as shown in
FIG. 3A , thefirst packaging piece 112 can be configured for packaging reuse, such that thefirst packaging piece 112 can include attach/fold pieces connected by perforated borders, including -
- a) a top
center attachment piece 304 a, which is configured to be aligned with atop side 204 of thecabinet 200,- such that the top
center attachment piece 304 a is positioned in a top center of thefirst packaging piece 112, between atop fold piece 306 a and a bottomcenter attachment piece 303 a;
- such that the top
- b) a bottom
center attachment piece 303 a, which is configured to be aligned with afront face 203 of thecabinet 200,- such that the bottom
center attachment piece 303 a is positioned in a bottom center of thefirst packaging piece 112, between the topcenter attachment piece 304 a andbottom fold piece 307 a, such that a bottom side of the topcenter attachment piece 304 a is connected to a top side of the bottomcenter attachment piece 303 a, via an intermediate fold piece;
- such that the bottom
- c) a
top fold piece 306 a, which is configured to fold onto aback panel 206 of thecabinet 200,- such that the
top fold piece 306 a is positioned in a top of thefirst packaging piece 112, and connected to a top side of the topcenter attachment piece 304 a;
- such that the
- d) a top left
side fold piece 301 a, which is configured to fold onto aleft side 201 of thecabinet 200,- such that the top left
side fold piece 301 a is positioned in a top left side of thefirst packaging piece 112, and connected to a left side of the topcenter attachment piece 304 a;
- such that the top left
- e) a top right side fold
piece 302 a, which is configured to fold onto aright side 202 of thecabinet 200,- such that the top right side fold
piece 302 a is positioned in a top right side of thefirst packaging piece 112, and connected to a right side of the topcenter attachment piece 304 a;
- such that the top right side fold
- f) a bottom left
side fold piece 311 a, which is configured to fold onto aleft side 201 of thecabinet 200,- such that the bottom left
side fold piece 311 a is positioned in a bottom left side of thefirst packaging piece 112, and connected to a left side of the bottomcenter attachment piece 303 a;
- such that the bottom left
- g) a bottom right side fold
piece 312 a, which is configured to fold onto aright side 202 of thecabinet 200,- such that the bottom right side fold
piece 312 a is positioned in a bottom right side of thefirst packaging piece 112, and connected to a right side of the bottomcenter attachment piece 303 a; and
- such that the bottom right side fold
- h) a
bottom fold piece 307 a, which is configured to fold onto abottom panel 205 of thecabinet 200,- such that the
bottom fold piece 307 a is positioned in a bottom of thefirst packaging piece 112, and connected to a bottom side of the bottomcenter attachment piece 303 a.
- such that the
- a) a top
- In a related embodiment, as shown in
FIG. 3B , thesecond packaging piece 122 can be configured for packaging reuse, such that thesecond packaging piece 122 can include attach/fold pieces connected by perforated borders, including -
- a) a
top fold piece 306 b, which is configured to be aligned with aback panel 206 of thecabinet 200,- such that the
top fold piece 306 b is positioned in a top of thesecond packaging piece 122, and connected to a top side of thecenter attachment piece 305 b;
- such that the
- b) a
center attachment piece 305 b, which is configured to be aligned with abottom panel 205 of thecabinet 200,- such that the
center attachment piece 305 b is positioned in a center of thesecond packaging piece 122, between atop fold piece 306 b and abottom fold piece 308 b;
- such that the
- c) a
bottom fold piece 308 b, which is configured to fold onto atoe panel 208 of thecabinet 200,- such that the
bottom fold piece 308 b is positioned in a bottom of thesecond packaging piece 122, and connected to a bottom side of thecenter attachment piece 305 b;
- such that the
- d) a bottom right side fold
piece 302 b, which is configured to fold onto aright side 202 of thecabinet 200,- such that the bottom right side fold
piece 302 b is positioned in a bottom right side of thesecond packaging piece 122, and connected to a right side of thecenter attachment piece 305 b;
- such that the bottom right side fold
- e) a bottom left
side fold piece 301 b, which is configured to fold onto aleft side 201 of thecabinet 200,- such that the bottom left
side fold piece 301 b is positioned in a bottom left side of thesecond packaging piece 122, and connected to a left side of thecenter attachment piece 305 b;
- such that the bottom left
- f) a top right side fold
piece 312 b, which is configured to fold onto aright side 202 of thecabinet 200,- such that the top right side fold
piece 312 b is positioned in a top right side of thesecond packaging piece 122, and connected to a right side of thetop fold piece 306 b; and
- such that the top right side fold
- g) a top left
side fold piece 311 b, which is configured to fold onto aleft side 201 of thecabinet 200,- such that the top left
side fold piece 311 b is positioned in a top left side of thesecond packaging piece 122, and connected to a left side of thetop fold piece 306 b.
- such that the top left
- a) a
- In a related embodiment, as shown in
FIG. 3C , thethird packaging piece 132 can be configured for packaging reuse, such that thethird packaging piece 132 can include attach/fold pieces connected by perforated borders, including -
- a) a
center attachment piece 301 c, which is configured to be aligned with aleft panel 201 of thecabinet 200,- such that the
center attachment piece 301 c is positioned in a center of thethird packaging piece 132, below atop fold piece 301 c-i and above abottom fold piece 311 c-i;
- such that the
- b) a
top fold piece 301 c-i, which is configured to fold back onto aninner side 211 of theleft panel 201 of thecabinet 200,- such that the
top fold piece 301 c-i is positioned in a top of thethird packaging piece 132, and connected to a top side of thecenter attachment piece 301 c;
- such that the
- c) a left
side fold piece 306 c, which is configured to fold onto aback panel 206 of thecabinet 200,- such that the left
side fold piece 306 c is positioned in a left side of thethird packaging piece 132, and connected to a left side of thecenter attachment piece 301 c;
- such that the left
- d) a right side fold
piece 303 c, which is configured to fold onto afront side 203 of thecabinet 200,- such that the right side fold
piece 303 c is positioned in a right side of thethird packaging piece 132, and connected to a right side of thecenter attachment piece 301 c;
- such that the right side fold
- e) a right bottom
corner fold piece 309 c, which is configured to fold onto atoe panel 208 of thecabinet 200,- such that the right bottom
corner fold piece 309 c is positioned in a right bottom corner of thethird packaging piece 132, and connected to a right bottom corner of thecenter attachment piece 301 c; and
- such that the right bottom
- f) a
bottom fold piece 311 c-i, which is configured to fold back onto aninner side 211 of theleft panel 201 of thecabinet 200,- such that the
bottom fold piece 311 c-i is positioned in a bottom of thethird packaging piece 132, and connected to a bottom side of thecenter attachment piece 301 c.
- such that the
- a) a
- In a related embodiment, as shown in
FIG. 3D , thefourth packaging piece 334 can be configured for packaging reuse, such that thefourth packaging piece 334 can include attach/fold pieces connected by perforated borders, including -
- a) a
center attachment piece 302 d, which is configured to be aligned with aright panel 202 of thecabinet 200,- such that the
center attachment piece 302 d is positioned in a center of thefourth packaging piece 334, below atop fold piece 302 d-i and above abottom fold piece 312 d-i;
- such that the
- b) a
top fold piece 302 d-i, which is configured to fold back onto aninner side 212 of theright panel 202 of thecabinet 200,- such that the
top fold piece 302 d-i is positioned in a top of thefourth packaging piece 334, and connected to a top side of thecenter attachment piece 302 d;
- such that the
- c) a right side fold
piece 306 d, which is configured to fold onto aback panel 206 of thecabinet 200,- such that the right side fold
piece 306 d is positioned in a right side of thefourth packaging piece 334, and connected to a right side of thecenter attachment piece 302 d;
- such that the right side fold
- d) a left
side fold piece 303 d, which is configured to fold onto afront side 203 of thecabinet 200,- such that the left
side fold piece 303 d is positioned in a left side of thefourth packaging piece 334, and connected to a left side of thecenter attachment piece 302 d;
- such that the left
- e) a left bottom
corner fold piece 309 d, which is configured to fold onto atoe panel 208 of thecabinet 200,- such that the left bottom
corner fold piece 309 d is positioned in a left bottom corner of thefourth packaging piece 334, and connected to a left bottom corner of thecenter attachment piece 302 d; and
- such that the left bottom
- f) a
bottom fold piece 312 d-i, which is configured to fold back onto aninner side 212 of theright panel 202 of thecabinet 200,- such that the
bottom fold piece 312 d-i is positioned in a bottom of thefourth packaging piece 334, and connected to a bottom side of thecenter attachment piece 302 d.
- such that the
- a) a
- In a further related embodiment,
FIGS. 6A, 6B, 6C, and 6D shows the first, second, third, andfourth packaging pieces 112 122 132 334 used for packaging reuse, such that thecabinet 200 is packaged with the first, second, third, andfourth packaging pieces 112 122 132 334, to form a repackagedcabinet 600. The perspective views ofFIGS. 6A, 6B, 6C, and 6D correspond substantially to the views ofFIGS. 6A, 6B, 6C, and 6D , respectively, with the first, second, third, andfourth packaging pieces 112 122 132 334 added. - In related embodiments, when the first, second, third, and
fourth packaging pieces 112 122 132 334 are used for packaging reuse to package the assembledcabinet 200, the first, second, third, andfourth packaging pieces 112 122 132 334 can be secured using packaging tape, staples, and/or other packaging fasteners. - In a related embodiment, as shown in
FIGS. 6A, 6B, 6C, and 6D : -
- a) The third and
fourth packaging pieces 132 334 can be attached to the cabinet first, for example using tape and/or staples, such that the third andfourth packaging pieces 132 334 are innermost positioned; - b) The
second packaging piece 122 can be attached next, for example using tape and/or staples, and partially overlapping the third andfourth packaging pieces 132 334, such that thesecond packaging piece 122 is intermediately positioned; and - c) The
first packaging piece 112 can be attached lastly, for example using tape and/or staples, and partially overlapping the third, fourth, andsecond packaging pieces 132 334 122, such that thefirst packaging piece 112 is outermost positioned.
- a) The third and
- In an embodiment, as illustrated in
FIGS. 5A and 5B , a method forflat packing furniture 500, can include: -
- a) Flat packing a
furniture item 502, wherein a plurality of parts for afurniture item 200 are flat packaged inside a plurality ofpackaging pieces 112 122 132 334, producing a plurality ofboxes 110 120 130; - b) Shipping the flat packed
furniture item 504, wherein the plurality of boxes is shipped from amanufacturing location 552 to areseller location 554, as shown inFIG. 5B , showing the sequence oflocations 550; - c) Unpacking the flat packed
furniture item 506, wherein the plurality of parts, comprising a plurality of sets of furniture parts, is unpackaged from the plurality of boxes; - d) Assembling the
furniture item 508, wherein thefurniture 200 item is assembled from the plurality of parts, to form an assembledfurniture item 200; - e) Re-packing the
furniture item 510, wherein the assembledfurniture item 200 is re-packaged with the plurality ofpackaging pieces 112 122 132 334, to form a repackagedfurniture item 600; and - f) Re-shipping the
furniture item 512, wherein there-packaged furniture item 600 is shipped from thereseller location 554 to acustomer location 556.
- a) Flat packing a
- Here has thus been described a multitude of embodiments of the flat packed
furniture system 100, and methods related thereto, which can be employed in numerous modes of usage. - The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention, which fall within the true spirit and scope of the invention.
- Many such alternative configurations are readily apparent, and should be considered fully included in this specification and the claims appended hereto. Accordingly, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and thus, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
Claims (20)
1. A method for flat packing furniture, comprising:
a) flat packing a furniture item, wherein a plurality of parts for the furniture item are flat packaged inside a plurality of packaging pieces, producing a plurality of boxes;
b) shipping the flat packed furniture item, wherein the plurality of boxes is shipped from a manufacturing location to a reseller location;
c) unpacking the flat packed furniture item, wherein the plurality of parts, comprising a plurality of sets of furniture parts, is unpackaged from the plurality of boxes;
d) assembling the furniture item, wherein the furniture item is assembled from the plurality of parts; and
e) re-packing the furniture item, wherein the assembled furniture item is re-packaged with the plurality of packaging pieces.
2. The method for flat packing furniture of claim 1 , further comprising:
re-shipping the furniture item;
wherein the re-packaged furniture item is shipped from the reseller location to a customer location.
3. The method for flat packing furniture of claim 1 , wherein the plurality of boxes further comprises:
a) a first box, comprising:
a first packaging piece; and
a first set of furniture parts, wherein the first set of furniture parts is flat packed inside the first packaging piece;
b) a second box, comprising:
a second packaging piece; and
a second set of furniture parts, wherein the second set of furniture parts is flat packed inside the second packaging piece; and
c) a third box, comprising:
a third packaging piece;
a fourth packaging piece; and
a third set of furniture parts, wherein the third set of furniture parts is flat packed inside the third and fourth packaging pieces;
wherein the first, second, and third sets of furniture parts are configured to be assemblable as the furniture item;
such that the packaging pieces are configured to be reused as packaging for the furniture item, such that the first, second, third, and fourth packaging pieces are configured to cover outer surfaces of the furniture item.
4. The method for flat packing furniture of claim 1 , wherein the furniture item is a cabinet.
5. The method for flat packing furniture of claim 3 , wherein the furniture item is a cabinet, and wherein:
a) the first set of furniture parts comprises face parts of the cabinet, comprising:
a face panel, which is a part of a front side of the cabinet;
doors, which are part of the front side of the cabinet; and
a back panel;
b) the second set of furniture parts comprise gut parts of the cabinet, comprising:
a bottom panel;
a toe panel; and
parts for drawer boxes; and
c) the third set of furniture parts comprise side parts of the cabinet, comprising:
a right side; and
a left side.
6. The method for flat packing furniture of claim 5 , wherein the second set of furniture parts further comprises a top panel.
7. The method for flat packing furniture of claim 3 , wherein the furniture item is a cabinet, wherein the first packaging piece comprises connected pieces, comprising:
a) a top center attachment piece, which is configured to be aligned with a top side of the cabinet;
b) a bottom center attachment piece, which is configured to be aligned with a front face of the cabinet, such that a bottom side of the top center attachment piece is connected to a top side of the bottom center attachment piece;
c) a top fold piece, which is configured to fold onto a back panel of the cabinet, such that the top fold piece is connected to a top side of the top center attachment piece;
d) a top left side fold piece, which is configured to fold onto a left side of the cabinet, such that the top left side fold piece is connected to a left side of the top center attachment piece;
e) a top right side fold piece, which is configured to fold onto a right side of the cabinet, such that the top right side fold piece is connected to a right side of the top center attachment piece;
f) a bottom left side fold piece, which is configured to fold onto a left side of the cabinet, such that the bottom left side fold piece is connected to a left side of the bottom center attachment piece;
g) a bottom right side fold piece, which is configured to fold onto a right side of the cabinet, such that the bottom right side fold piece is connected to a right side of the bottom center attachment piece; and
h) a bottom fold piece, which is configured to fold onto a bottom panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the bottom center attachment piece.
8. The method for flat packing furniture of claim 7 , wherein the connected pieces are connected by perforated borders.
9. The method for flat packing furniture of claim 3 , wherein the furniture item is a cabinet, wherein the second packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a bottom panel of the cabinet;
b) a top fold piece, which is configured to be aligned with a back panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a bottom fold piece, which is configured to fold onto a toe panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece;
d) a bottom right side fold piece, which is configured to fold onto a right side of the cabinet, such that the bottom right side fold piece is connected to a right side of the center attachment piece;
e) a bottom left side fold piece, which is configured to fold onto a left side of the cabinet, such that the bottom left side fold piece is connected to a left side of the center attachment piece;
f) a top right side fold piece, which is configured to fold onto a right side of the cabinet, such that the top right side fold piece is connected to a right side of the top fold piece; and
g) a top left side fold piece, which is configured to fold onto a left side of the cabinet, such that the top left side fold piece is connected to a left side of the top fold piece.
10. The method for flat packing furniture of claim 3 , wherein the furniture item is a cabinet, wherein the third packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a left panel of the cabinet;
b) a top fold piece, which is configured to fold back onto an inner side of the left panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a left side fold piece, which is configured to fold onto a back panel of the cabinet, such that the left side fold piece is connected to a left side of the center attachment piece;
d) a right side fold piece, which is configured to fold onto a front side of the cabinet, such that the right side fold piece is connected to a right side of the center attachment piece; and
e) a bottom fold piece, which is configured to fold back onto an inner side of the left panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece.
11. The method for flat packing furniture of claim 3 , wherein the furniture item is a cabinet, wherein the fourth packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a right panel of the cabinet;
b) a top fold piece, which is configured to fold back onto an inner side of the right panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a right side fold piece, which is configured to fold onto a back panel of the cabinet, such that the right side fold piece is connected to a right side of the center attachment piece;
d) a left side fold piece, which is configured to fold onto a front side of the cabinet, such that the left side fold piece is connected to a left side of the center attachment piece; and
e) a bottom fold piece, which is configured to fold back onto an inner side of the right panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece.
12. A method for flat packing furniture, comprising:
a) flat packing a furniture item, wherein a plurality of parts for the furniture item are flat packaged inside a plurality of packaging pieces, producing a plurality of boxes;
b) shipping the flat packed furniture item, wherein the plurality of boxes is shipped from a manufacturing location to a reseller location;
c) unpacking the flat packed furniture item, wherein the plurality of parts, comprising a plurality of sets of furniture parts, is unpackaged from the plurality of boxes;
d) assembling the furniture item, wherein the furniture item is assembled from the plurality of parts; and
e) re-packing the furniture item, wherein the assembled furniture item is re-packaged with the plurality of packaging pieces;
wherein the plurality of boxes further comprises:
a first box, comprising:
a first packaging piece; and
a first set of furniture parts, wherein the first set of furniture parts is flat packed inside the first packaging piece;
a second box, comprising:
a second packaging piece; and
a second set of furniture parts, wherein the second set of furniture parts is flat packed inside the second packaging piece; and
a third box, comprising:
a third packaging piece;
a fourth packaging piece; and
a third set of furniture parts, wherein the third set of furniture parts is flat packed inside the third and fourth packaging pieces;
wherein the first, second, and third sets of furniture parts are configured to be assemblable as the furniture item;
such that the packaging pieces are configured to be reused as packaging for the furniture item, such that the packaging pieces are configured to cover outer surfaces of the furniture item.
13. The method for flat packing furniture of claim 12 , further comprising:
re-shipping the furniture item;
wherein the re-packaged furniture item is shipped from the reseller location to a customer location.
14. The method for flat packing furniture of claim 12 , wherein the furniture item is a cabinet, and wherein:
a) the first set of furniture parts comprises face parts of the cabinet, comprising:
a face panel, which is a part of a front side of the cabinet;
doors, which are part of the front side of the cabinet; and
a back panel;
b) the second set of furniture parts comprise gut parts of the cabinet, comprising:
a bottom panel;
a toe panel; and
parts for drawer boxes; and
c) the third set of furniture parts comprise side parts of the cabinet, comprising:
a right side; and
a left side.
15. The method for flat packing furniture of claim 14 , wherein the second set of furniture parts further comprises a top panel.
16. The method for flat packing furniture of claim 12 , wherein the furniture item is a cabinet, wherein the first packaging piece comprises connected pieces, comprising:
a) a top center attachment piece, which is configured to be aligned with a top side of the cabinet;
b) a bottom center attachment piece, which is configured to be aligned with a front face of the cabinet, such that a bottom side of the top center attachment piece is connected to a top side of the bottom center attachment piece;
c) a top fold piece, which is configured to fold onto a back panel of the cabinet, such that the top fold piece is connected to a top side of the top center attachment piece;
d) a top left side fold piece, which is configured to fold onto a left side of the cabinet, such that the top left side fold piece is connected to a left side of the top center attachment piece;
e) a top right side fold piece, which is configured to fold onto a right side of the cabinet, such that the top right side fold piece is connected to a right side of the top center attachment piece;
f) a bottom left side fold piece, which is configured to fold onto a left side of the cabinet, such that the bottom left side fold piece is connected to a left side of the bottom center attachment piece;
g) a bottom right side fold piece, which is configured to fold onto a right side of the cabinet, such that the bottom right side fold piece is connected to a right side of the bottom center attachment piece; and
h) a bottom fold piece, which is configured to fold onto a bottom panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the bottom center attachment piece.
17. The method for flat packing furniture of claim 16 , wherein the connected pieces are connected by perforated borders.
18. The method for flat packing furniture of claim 12 , wherein the furniture item is a cabinet, wherein the second packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a bottom panel of the cabinet;
b) a top fold piece, which is configured to be aligned with a back panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a bottom fold piece, which is configured to fold onto a toe panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece;
d) a bottom right side fold piece, which is configured to fold onto a right side of the cabinet, such that the bottom right side fold piece is connected to a right side of the center attachment piece;
e) a bottom left side fold piece, which is configured to fold onto a left side of the cabinet, such that the bottom left side fold piece is connected to a left side of the center attachment piece;
f) a top right side fold piece, which is configured to fold onto a right side of the cabinet, such that the top right side fold piece is connected to a right side of the top fold piece; and
g) a top left side fold piece, which is configured to fold onto a left side of the cabinet, such that the top left side fold piece is connected to a left side of the top fold piece.
19. The method for flat packing furniture of claim 12 , wherein the furniture item is a cabinet, wherein the third packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a left panel of the cabinet;
b) a top fold piece, which is configured to fold back onto an inner side of the left panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a left side fold piece, which is configured to fold onto a back panel of the cabinet, such that the left side fold piece is connected to a left side of the center attachment piece;
d) a right side fold piece, which is configured to fold onto a front side of the cabinet, such that the right side fold piece is connected to a right side of the center attachment piece; and
e) a bottom fold piece, which is configured to fold back onto an inner side of the left panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece.
20. The method for flat packing furniture of claim 12 , wherein the furniture item is a cabinet, wherein the fourth packaging piece comprises connected pieces, comprising:
a) a center attachment piece, which is configured to be aligned with a right panel of the cabinet;
b) a top fold piece, which is configured to fold back onto an inner side of the right panel of the cabinet, such that the top fold piece is connected to a top side of the center attachment piece;
c) a right side fold piece, which is configured to fold onto a back panel of the cabinet, such that the right side fold piece is connected to a right side of the center attachment piece;
d) a left side fold piece, which is configured to fold onto a front side of the cabinet, such that the left side fold piece is connected to a left side of the center attachment piece; and
e) a bottom fold piece, which is configured to fold back onto an inner side of the right panel of the cabinet, such that the bottom fold piece is connected to a bottom side of the center attachment piece.
Priority Applications (1)
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US16/399,613 US20190254423A1 (en) | 2016-05-05 | 2019-04-30 | System and method for flat packed furniture to enable reuse of packaging materials |
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US201662332432P | 2016-05-05 | 2016-05-05 | |
US15/584,924 US10306979B2 (en) | 2016-05-05 | 2017-05-02 | System and method for flat packed furniture to enable reuse of packaging materials |
US16/399,613 US20190254423A1 (en) | 2016-05-05 | 2019-04-30 | System and method for flat packed furniture to enable reuse of packaging materials |
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US15/584,924 Continuation US10306979B2 (en) | 2016-05-05 | 2017-05-02 | System and method for flat packed furniture to enable reuse of packaging materials |
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US20190254423A1 true US20190254423A1 (en) | 2019-08-22 |
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US16/399,613 Abandoned US20190254423A1 (en) | 2016-05-05 | 2019-04-30 | System and method for flat packed furniture to enable reuse of packaging materials |
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US20210093082A1 (en) * | 2019-09-26 | 2021-04-01 | Liberty Hardware Mfg. Corp. | Modular storage system |
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US7032747B2 (en) * | 2002-12-02 | 2006-04-25 | Hni Technologies Inc. | Reusable packaging system |
US20080120945A1 (en) | 2006-10-25 | 2008-05-29 | Staples, The Office Superstore Llc | Parts kit |
US7748528B2 (en) * | 2008-04-04 | 2010-07-06 | Target Brands, Inc. | Convertible packaging |
US20100277046A1 (en) | 2009-04-29 | 2010-11-04 | Ya-Chi Huang | Modular flat pack computer cabinet |
US9213367B1 (en) | 2009-12-30 | 2015-12-15 | Emc Corporation | Kit for shipping an electrical cabinet |
US9585482B2 (en) | 2011-06-23 | 2017-03-07 | Zachary Rotholz | Corrugated fiberboard constructions |
US9380877B2 (en) * | 2011-11-23 | 2016-07-05 | Ashley Furniture Industries, Inc. | Ready to assemble furniture system |
KR20130094427A (en) * | 2012-02-16 | 2013-08-26 | 이정희 | Personal furniture set |
GB2520509B (en) * | 2013-11-21 | 2018-04-11 | William Hardie Design | Furniture system |
US10076185B1 (en) * | 2015-01-21 | 2018-09-18 | Kolcraft Enterprises, Inc. | Furniture kits and methods of making the same |
US10362860B2 (en) * | 2015-12-15 | 2019-07-30 | Zinus Inc. | Flat pack end table and coffee table |
-
2017
- 2017-05-02 US US15/584,924 patent/US10306979B2/en not_active Expired - Fee Related
- 2017-05-04 WO PCT/US2017/031080 patent/WO2017192860A1/en active Application Filing
-
2019
- 2019-04-30 US US16/399,613 patent/US20190254423A1/en not_active Abandoned
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20240108127A1 (en) * | 2022-09-29 | 2024-04-04 | Michael H Panosian | Foldable cabinet assembly |
Also Published As
Publication number | Publication date |
---|---|
US10306979B2 (en) | 2019-06-04 |
WO2017192860A1 (en) | 2017-11-09 |
US20170318960A1 (en) | 2017-11-09 |
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