US20200405057A1

US20200405057A1 - Fastenerless and adhesiveless furniture pieces

Info

Publication number: US20200405057A1
Application number: US16/458,036
Authority: US
Inventors: Jason Lawrence Prentice; Lawrence James Prentice
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-06-29
Filing date: 2019-06-29
Publication date: 2020-12-31

Abstract

Fastenerless and adhesiveless furniture pieces, which in various embodiments may include chairs, steps, adirondack chairs, footrests, and other furniture pieces, may each include a first panel, a second panel, and a plurality of support panels. The first and second panels may each one or more outwardly extending engagement members. The engagement members may each include a tapered void that mates with one of the support panels. The first and second panels may include curved edges that complement one another. The first panel, the second panel, and the plurality of support panels may be securely coupled to form the furniture piece, without relying on any fasteners or adhesives, when the complementary curved edges of the first and second panels are forced into abutting engagement with one another.

Description

BACKGROUND

Technical Field

The present disclosure concerns furniture. More particularly, the present disclosure relates to fastenerless and adhesiveless furniture pieces.

Description of the Related Art

Furniture plays an important part of every day life in modern society. From homes to businesses to public spaces like parks and boardwalks, furniture is an essential element of human productivity, recreation, comfort, and design.
Many types of furniture are manufactured or assembled using fasteners (e.g., cam fittings, anchors, dowels, screws, nails, or staples). Others are assembled using adhesives (e.g., wood glue or epoxy) either alone or in addition to fasteners. Although furniture pieces assembled with fasteners and adhesives feature decent structural integrity, they are expensive and cumbersome to ship from the manufacturer. Moreover, such pieces are difficult for consumers to assemble on their own, require particular tools, and cannot easily be disassembled and relocated.
Other types of furniture referred to by various names such as “ready-to-assembly” furniture, “knock-down” furniture, or “flat-pack” furniture (as made famous by IKEA of Leiden, Netherlands) are manufactured from inexpensive materials and are design to be assembled by consumers. Although these types of furniture rarely include adhesives, they rely on numerous fasteners and the consumer's ability to follow lengthy assembly instructions. Moreover, because they are comprised of inexpensive materials held together by numerous connection points, they tend to lose structural integrity over time.
Previous industry attempts at producing fastenerless and adhesiveless furniture have proven suboptimal. Some such attempts have produced furniture that is free of any fasteners or adhesives, but requires significant manual force to assemble properly. Many attempted designs are complicated and require the consumer to fit numerous pieces together like a puzzle or else the design cannot achieve structural integrity (or cannot be assembled at all). Others rely on the use of thin tabs that are subjected to twisting and bending forces and, as a result, render the design susceptible to breakage.
Given the foregoing limitations, consumers need simple, inexpensive, easy-to-assemble furniture pieces that possess enhanced structural integrity without relying on fasteners or adhesives.

SUMMARY OF THE CLAIMED INVENTION

A fastenerless and adhesiveless furniture piece includes a first panel, a second panel, and a plurality of support panels. The first panel includes a first edge, a second edge, a top surface disposed between the first edge and the second edge, a bottom surface disposed opposite the top surface between the first edge and the second edge, side edges each disposed between the first edge and the second edge, and an engagement member that extends outwardly from each side edge. The second edge includes a curve. Each engagement member includes a tapered void. The second panel includes a first edge, a second edge, a top surface disposed between the first edge and the second edge, a bottom surface disposed opposite the top surface between the first edge and the second edge, side edges each disposed between the first edge and the second edge, and an engagement member that extends outwardly from each side edge. The first edge includes a curve. Each engagement member includes a tapered void. Each of the plurality of support panels includes a first slot that mates with an engagement member of the first panel and a second slot that mates with an engagement member of the second panel. The first panel, the second panel, and the plurality of support panels are securely coupled to form the furniture piece when the second edge of the first panel is forced into abutting engagement with the first edge of the second panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 2 is a front view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 3 is a rear view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 4 is a top view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 5 is a bottom view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 6 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 7 is an exploded perspective view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 8 is an exploded front view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 9 is an exploded rear view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 10 is an exploded top view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 11 is an exploded bottom view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 12 is an exploded side view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration.

FIG. 13 is a normal view of an exemplary first panel.

FIG. 14 is a normal view of an exemplary second panel.

FIG. 15 is a zoomed normal view of an exemplary engagement member and tapered void.

FIG. 16 is a normal view of an exemplary support panel.

FIG. 17 is a flow chart of an operational procedure for assembling an exemplary fastenerless and adhesiveless furniture piece.

FIG. 18 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 19 is a front view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 20 is a rear view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 21 is a top view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 22 is a bottom view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 23 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration.

FIG. 24 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 25 is a front view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 26 is a rear view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 27 is a top view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 28 is a bottom view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 29 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 30 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 31 is a zoomed perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 32 is a top view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

FIG. 33 is a bottom view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.

DETAILED DESCRIPTION

Fastenerless and adhesiveless furniture pieces, which in various embodiments may include a chair, a step, an adirondack chair, a footrest, or other furniture pieces, may each include a first panel, a second panel, and a plurality of support panels. The first and second panels may each include one or more outwardly extending engagement members. The engagement members may each include a tapered void that mates with one of the support panels. The first and second panels may include curved edges that complement one another and aid in assembly. The first panel, the second panel, and the plurality of support panels may be securely coupled to form the assembled furniture piece without relying on any fasteners or adhesives when the complementary curved edges of the first and second panels are forced into abutting engagement with one another. The abutting engagement creates a sturdy and robust tension joint that not only creates tension at the immediate location of the joint, but also has a ripple effect that causes stabilizing tension to permeate throughout the furniture piece.
In some embodiments, when the curved edge of the first panel is forced into abutting engagement with the complementary curved edge of the second panel, the engagement members of the first panel are simultaneously forced into abutting engagement with corresponding second slots in the support panels. At the same time, by virtue of the force applied to curved edge of the second panel, the engagement members of the second panel may be moved into abutting engagement with corresponding first slots in the support panels. Thus, the first panel may effectively be “locked” in place between the tension joint created between the first and second panels and the tension joints created where the engagement members of the first panel abuttingly engage the second slots of the support panels. The second panel may likewise be effectively “locked” in place between the tension joint created between the first and second panels and the tension joints created where the engagement members of the second panel abuttingly engage the first slots of the support panels. As a result, the furniture pieces may be securely assembled in minimal steps, with minimal force required from the consumer, and without the need for tools, fasteners, or adhesives. The furniture pieces may be easily disassembled for storage, shipping, or relocation by reversing the few required assembly steps.
Because the furniture pieces may be assembled using minimal steps (e.g., as few as four to six, only one of which requires any force in some embodiments), do not include small components that would otherwise need to be handled and manipulated during assembly, and do not require the use of any tools, fasteners, or adhesives, they can easily be assembled even by a user wearing gloves or working under challenging circumstances (e.g., underwater, in extreme cold, or even in space). Unlike prior industry attempts to produce easy-to-assembly fastenerless furniture, the furniture pieces disclosed herein cannot be fully assembled notwithstanding a mistake made during the assembly process. Namely, the unique yet simple design ensures that consumers either fully and completely assemble the furniture pieces with success or become immediately aware that they skipped a step or are missing a component. Accordingly, consumers are spared the all-too-common and frustrating scenario in which a mistake made halfway through assembly is only discovered upon stepping back and inspecting the final product.
When disassembled, the furniture piece components lay flat and occupy a small space. As a result, the furniture pieces may be shipped, stored, and relocated with reduced cost and effort. Moreover, they may be packed in large quantities on a single pallet, which facilitates their ability to be used in disaster relief efforts (e.g., following an earthquake, or tsunami that has destroyed traditional furniture, such as chairs, desks, tables, beds, trunks, chests, and other important furniture pieces).
Additionally, the furniture pieces, by virtue of their reduced expense and of being easily assembled and disassembled, are convenient for use in camps, parks, picnic areas, tailgates, or other outdoor areas in addition to traditional furniture environments (e.g., homes, apartments, offices, dorm rooms, apartments, cottages, and the like). The furniture pieces may be finished with antimicrobial agents and may be dishwasher safe. As a result, they withstand soiling better than traditional furniture, are easier to clean, and are safer for use in schools, daycares, churches, and other child-centered environments.
The various components, which as noted above may include as few components as a first panel, a second panel, and a plurality (e.g., as few as two) of support members, may be manufactured from flat stock or sheet material (e.g., plastic, sheet metal, bamboo or other wood, medium density fiberboard, a composition of plastic and wood, or other materials) using known computer-aided manufacturing methods and other mass production methods. The components may be manufactured using, for instance, a computerized numerical control machining system. The system may employ routing, laser cutting, plasma cutting, water cutting, or any number of other known manufacturing methods. As a result, the components may be manufactured in an inexpensive yet easily repeatable manner. The unique design of the fastenerless and adhesiveless furniture pieces allows for flexible dimensional tolerances during manufacturing—one of many aspects that sets the furniture pieces apart from previous industry attempts to offer fastenerless furniture. Because the tolerances are more flexible, fewer components need be discarded during manufacturing, which in turn results in higher yields. By extension, the higher tolerances also result in less environmental impact and cost in terms of raw material waste and energy consumption during manufacturing and shipping.
The furniture pieces described herein are merely examples of the numerous embodiments possible in view of the present disclosure. For instance, although the present disclosure focuses on a chair for purposes of illustration, persons of ordinary skill in the art will readily recognize and appreciate that many other types of furniture pieces may be manufactured based on the principals described herein. Descriptions of particular embodiments (e.g., a chair, a step, an Adirondack chair, a footrest, or the like) are merely exemplary and are in no way limiting. Many other forms of furniture will readily suggest themselves to persons skilled in the art after viewing the present disclosure, including but not limited to benches, tables, shelves, planter boxes, beds, desks, and stools.
FIG. 1 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration. As illustrated in FIG. 1, the exemplary furniture piece is a chair. The chair may exist in a variety of sizes, ranging from a size suitable for a toddler, to a size appropriate for a primary or secondary school student, to young or full-grown adults. In the example shown in FIG. 1, the fastenerless and adhesiveless chair is sized to suit toddlers. The fastenerless and adhesiveless furniture piece may include a first panel (shown in green in FIG. 1), a second panel (shown in yellow in FIG. 1), and a plurality of support panels (shown in pink and orange in FIG. 1) securely coupled together to form a sturdy and attractive furniture piece. The first panel may include a first edge (oriented at the top of the chair in FIG. 1), a second edge (oriented at the interface between the first panel and the second panel in FIG. 1), a top surface disposed between the first edge and the second edge, and a bottom surface disposed opposite the top surface between the first edge and the second edge. The second edge may include a curve. The first panel may further include a plurality of side edges each disposed between the first edge and the second edge. An engagement member may extend outwardly from each side edge of the first panel. Each engagement member may include a tapered void or cutout region such that the engagement member is L-shaped or hook-shaped when viewed in its entirety. The first panel may also include a handle to ensure that the furniture piece is easily manipulatable even in fully assembled form. The handle may be a cutout as shown in FIG. 1, or it may be a relief or elevated surface of the top surface or a rear surface of the first panel. The handle may form an image or symbol, such as a corporate logo.
The second panel may include a first edge (oriented toward the rear of the chair at the interface between the first panel and the second panel in FIG. 1), a second edge (oriented toward the front of the chair in FIG. 1), a top surface disposed between the first edge and the second edge, and a bottom surface disposed opposite the top surface between the first edge and the second edge. The second panel may include a plurality of side edges each disposed between the first edge and the second edge. An engagement member may extend outwardly from each side edge. The first edge may include a curve. As described later in further detail, the curve of the first edge of the second panel may be fully or partially complementary to the curve of the second edge of the first panel. Each engagement member includes a tapered void or cutout region such that the engagement member is L-shaped or hook-shaped when viewed in its entirety.
The plurality of support panels may each include a first slot that mates with art engagement member of the first panel (illustrated in FIG. 1 as the vertical slot to which the green engagement member of the first panel is mated) and a second slot that mates with an engagement member of the second panel (illustrated in FIG. 1 as the horizontal slot to which the yellow engagement member of the second panel is mated). The first panel, the second panel, and the plurality of support panels may be securely coupled to form the furniture piece when the second edge of the first panel is forced into abutting engagement with the first edge of the second panel.
FIGS. 2 and 3 are front and rear views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration. As noted above and as shown in further detail in FIGS. 2 and 3, the second edge of the first panel may include a curve. The curve of the second edge of the first panel may be convex with respect to a center of the top surface of the first panel. When the first panel, the second panel, and the plurality of support panels are securely coupled to form the furniture piece (e.g., when the second edge of the first panel is forced into abutting engagement with the first edge of the second panel), the second edge of the first panel may extend partially or completely beyond the complementarily curved first edge of the second panel. Accordingly, just as easily as the furniture piece may be assembled, it may be easily disassembled by turning the piece over and forcing the first panel out of abutting engagement with the second panel.
FIGS. 4 and 5 are top and bottom views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration. As shown in further detail in FIGS. 4 and 5, the curve of the first edge of the second panel may include a concave curve.
FIG. 6 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a fully assembled configuration. As shown in exemplary furniture piece of FIG. 6, the engagement members of the first and second panels may extend beyond the length of the corresponding slots of the support panels to which they each mate. Moreover, as demonstrated by the support panels shown in FIG. 6, all of the components of the furniture piece may feature smooth surfaces and rounded edges and corners to ensure safety and comfort during use. The smooth surfaces and rounded edges may be of particular advantage when the furniture piece, like the toddler chair shown in FIG. 6, is sized for use by toddlers or other children.
FIG. 7 is an exploded perspective view of an exemplary fastenerless and adhesiveless furniture piece. As illustrated in FIG. 7, the furniture piece may include as few as four components, two of which may be identical mirror images (thus reducing the number of manufactured pieces to three). Moreover, the first panel, the second panel, and the support panels may include the same uniform thickness. As a result, all of the components may be cut from the same inventory or same sheet of material, which in turn reduces the complexity and cost of manufacturing. The low profile of the components further facilitates storage, shipping, and relocation of the furniture pieces.
FIGS. 8 and 9 are exploded front and rear views, respectively, of an exemplary fastenerless and adhesiveless furniture piece. The convex curve of the second edge of the first panel is prominently visible in FIGS. 8 and 9.
FIGS. 10 and 11 are exploded top and bottom views, respectively, of an exemplary fastenerless and adhesiveless furniture piece. The engagement members extending outwardly from the side edges of the second panel, each of which include a tapered void or cutout region, are prominently visible in FIGS. 10 and 11. The concave curve of the first edge of the second panel is also prominently visible in FIG. 11.
FIG. 12 is an exploded side view of an exemplary fastenerless and adhesiveless furniture piece. As shown in FIG. 12, the first edge of the first panel may extend above a top edge of the support panels before the furniture piece is fully assembled. As a result, as discussed later in further detail, the first edge of the first panel is made prominently available for manipulation by the consumer (e.g., through a downward force that drives the first panel into abutting engagement with the second panel and the support panels, which in turn also forces the second panel into abutting engagement with the support panels).
FIGS. 13 and 14 are normal views, respectively, of an exemplary first panel and an exemplary second panel. The engagement members extending form the side edges of each of the first panel and second panel are shown in further detail in FIG. 15.
FIG. 15 is a zoomed normal view of an exemplary engagement member and tapered void or cutout. The engagement member may include a void or cutout region so as to give the engagement member an L-shape or hook-shape when viewed in its entirety. The void may include a plurality of sides, illustrated in the orientation of FIG. 15 as a flat inner side, a tapered outer side, and a flat upper side. In other embodiments, the inner side may be tapered either instead of or in addition to the tapered outer side. By virtue of the tapered side, the void may include a tapered width proceeding from the opening of the void toward the flat upper side. A first width, referred to for illustrative purposes as the outer width furthest from the flat upper side, may be greater than a thickness of the support panel. Because the first width is greater than the thickness of the support panel, it may mate with or receive the support panel (e.g., at the flat edge forming the slot in the support panel) with little resistance or friction.
A second width, referred to for illustrative purpose as the inner width closest to the flat upper side of the void, may be less than the thickness of the support panel. Because the second width is less than the thickness of the support panel, it may only mate with or receive the support panel when the support panel is forced into the second width. When the support panel is forced into the second width, the second width is forced to expand slightly to accommodate the support panel. As a result, the support panel becomes abuttingly engaged with the void through the tension and friction that arises between the engagement member at the second width and the support member.
When the furniture piece is fully assembled, the support panel may further be forced into abutting engagement with the engagement member at the upper flat surface of the void. Thus, like the flat upper surface of the void, the edge of the support member that abuttingly engages the flat upper surface may likewise be flat so as to net out or create a positive stop. In embodiments like that illustrated in FIG. 15, each engagement member may abuttingly engage the support panel at three distinct engagement points: at the flat inner side, at the flat upper side, and at the tapered outer side at the inner width of the void. As a result, although the tensioned interface between the first panel and the second panel may constitute the primary joint providing enhanced structural integrity to the assembled furniture piece, the many engagement members make such stability even more robust.
As further shown in FIG. 15, the void may include one or more rounded regions adjacent to the flat upper side. The rounded regions may serve as turn-around zones for a router or other cutting instrument during the manufacturing process. By including the rounded regions, a router-based computerized numerical control machining system may successfully create the flat upper surface in the void and then retreat cleanly from the void. Because the flat-on-flat or positive stop engagement between the support panel and each engagement member further bolsters the stability of the furniture piece, and because computerized numerical control machining offers an inexpensive and efficient manufacturing process, the inclusion of the rounded regions in the voids in and of itself constitutes an improvement over prior industry attempts to create fastenerless furniture. In some embodiments, the void may omit the rounded regions and instead use straight regions (e.g., where a flat blade is used during manufacturing rather than a round router bit).
FIG. 16 is a normal view of an exemplary support panel. The rounded regions described in the context of FIG. 15 are further visible in FIG. 16.
FIG. 17 is a flow chart illustrating an exemplary operational procedure for assembling an exemplary fastenerless and adhesiveless furniture piece. In a first step, a method for assembling the furniture piece may include inserting a first engagement member of the second panel into the corresponding first slot of a first support panel. In a second step, the method may include inserting a first engagement member of the first panel into the corresponding second slot of the first support panel. The method may further include inserting a second engagement member of the second panel into a corresponding first slot of a second support panel. The method may also include inserting a second engagement member of the first panel into a corresponding second slot of the second support panel. The order of the foregoing steps are merely exemplary and may be reversed.
In a further step, the first and second engagement members of the second panel may be moved toward abutting engagement with the corresponding first slots of the first and second support panels. As discussed above in the context of FIG. 15, the abutting engagement may be achieved at one or more tension points, one of which may include a flat-on-flat positive stop engagement between a flat side of the engagement member forming the void or cutout region and a flat edge of the slot of the support member. In many cases, however, the engagement members of the second panel need not be brought fully into abutting engagement with the corresponding first slots of the support panels at the presently described stage of the method. Rather, the second panel may simply be moved toward an abutting engagement so as to allow the second edge of the first panel sufficient clearance to get behind the first edge of the second panel and serve as a tension lever. Thus, at the presently described stage of the method, in some cases the various components may remain loose and may not be securely engaged with one another.
In a further step, the method may include moving the first and second engagement members of the first panel into abutting engagement with the corresponding second slots of the first and second support panels. The engagement may occur as described in the context of FIG. 15 and elsewhere. Namely, forcing each engagement member of the second panel into abutting engagement with a corresponding second slot of each support panel may include forcing the support panel into the tapered void of the engagement member. Forcing the support panel into the tapered void of the engagement member may include forcing the support panel through the outer width of the tapered void and into the inner width of the tapered void.
As the engagement members of the first panel are forced into abutting engagement with the corresponding second slots of the support panels, the second edge of the first panel may likewise be driven into abutting engagement with the first edge of the second panel. As noted above, the curve of the second edge of the first panel may be convex with respect to a center of the top surface of the first panel. The curve of the first edge of the second panel may complement the curve of the second edge of the first panel. The curve of the first edge of the second panel may, for instance, be concave with respect to a center of the top surface of the second panel. The complementary curves may permit the convex curve of the second edge of the first panel to abuttingly engage the first edge of the second panel primarily at the center of the edges. In some cases, the complementary curves may be not be precisely complementary such that the centers of the edges engage while allowing the distal regions of the edges to remain unengaged.
As the first panel is driven into abutting engagement with the second panel as described above, the engagement members of the first panel are forced into abutting engagement with the corresponding second slots of the support panels. At the same time, the displacement of the area of the first edge of the second panel by the area of the second edge of the first plane causes the second panel is be forced forward. By virtue of being forced forward, the engagement members of the second panel are forced into full abutting engagement with the corresponding second slots of the support members. Thus, the first panel acts as a tension lever that creates a robust tension joint at the interface between the second edge of the first panel and the first edge of the second panel. The first panel is securely coupled to the support panels by virtue of its engagement members abuttingly engaging the corresponding first slots of the support members. The tension placed on the second panel by the first panel causes the second panel to come into abutting engagement with the second slots of the support panels, thereby securing the second panel to both the support members and to the first panel. When the first panel applies tension to the second panel, it causes the second panel to flex slightly, which in turn further stiffens and stabilizes the various tension joints generated throughout the assembled furniture piece. The extent of flexing may be controlled and optimized for a given furniture piece by altering the placement of the first slots of the support members. Doing so allows the moment arm or lever created by the first panel to be adjusted to achieve the desired forces necessary to assembly or disassemble the furniture piece without the need for tools, fasteners, or adhesives. Using the curved edges of the first and second panels and adjusting the length of the moment arm to control the tension joint creating between the panels offers the ability to accommodate a wide variety of flat stock materials.
FIG. 18 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration. As shown in FIG. 18, the engagement members of the first and second panels have been mated with or inserted into the corresponding slots of the support members, but neither panel has been moved toward an abuttingly engaged configuration. Thus, as shown in FIG. 18, the first panel remains elevated above a top edge of the support panels so as to provide a broad surface by which a consumer may manipulate the first panel (e.g., by placing one or both hands, whether gloved or ungloved, upon the first edge and driving downward towards the ground). The second panel remains positioned toward the rear of the support panels, which as shown in FIG. 18 results in a lack of clearance by which the first panel might otherwise get behind the second panel to serve as a moment arm. At the stage of assembly shown in FIG. 18, the various components may still be loose and may not be securely coupled together so as to form a stabile furniture piece.
FIGS. 19 and 20 are front and rear views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration. As shown in FIGS. 19 and 20, the first panel has yet to be driven into abutting engagement with the second panel. Thus, a gap between the two panels is visible.
FIGS. 21 and 22 are top and bottom views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration. The lack of clearance available for the first panel to get behind the second panel and act as a moment arm is highlighted in FIGS. 21 and 22. The lack of clearance available at the stage shown in FIGS. 21 and 22 ensures that only minimal clearance is provided for the first panel when the second panel has been moved forward toward. The minimal level of clearance ensures that the second panel overlaps the first panel slightly and allows the first panel to act as a moment arm that forces the second panel into abutting engagement with the second slots of the support panels.
FIG. 23 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a partially assembled configuration. As shown in FIG. 23, neither of the engagement members has been moved into abutting engagement with the corresponding slots of the support panel (e.g., there is a gap between the flat surface of the void of the engagement member and the flat edge of the slot in the support panel).
FIG. 24 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration. As shown in FIG. 24, in contrast to FIG. 18, the engagement members of the second panel have been moved forward toward abutting engagement with the second slots of the support panels. As a result, in further contrast to the assembly stage shown in FIG. 18, the first panel has sufficient clearance to get behind the second panel and act as a moment arm to create a robust tension joint that secures both the first panel and the second panel to the support panels as well as to each other.
FIGS. 25 and 26 are front and rear views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.
FIGS. 27 and 28 are top and bottom views, respectively, of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration. As illustrated in FIGS. 27 and 28, the first panel is omitted to further highlight the forward position of the second panel after the engagement members of the second panel have been moved towards abutting engagement with the second slots of the support panels.
FIG. 29 is a side view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration. In contrast to the assembly state illustrated in FIG. 23, in FIG. 29 the engagement member of the second panel has been moved toward abutting engagement with the second slots of the support panels.
FIG. 30 is a perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration. As shown in FIG. 30, the second panel has been moved forward such that its engagement members are near abutting engagement with the second slots of the support members. Additionally, the first panel has been driven partially downward such that its engagement members are closer to abutting engagement with the first slots of the support panels.
FIG. 31 is a zoomed perspective view of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration. FIG. 31 illustrates an intermediate phase in which the second edge of the first panel and the first edge of the second panel are nearly in abutting engagement with one another. FIG. 31 highlights that, while the position of the second panel after having been moved toward abutting engagement with the second slots of the support panels provides clearance for the first panel, the clearance is only partial. Because the clearance is only partial, the first panel may displace a portion of the first edge of the second panel to get into a position in which the first panel can serve as a moment arm and create a robust tension joint at the interface between the two panels.
FIG. 32 and FIG. 33 are top and bottom views of an exemplary fastenerless and adhesiveless furniture piece in a further partially assembled configuration.
As discussed above, the furniture pieces described herein are merely examples of the numerous embodiments possible in view of the present disclosure. For instance, although the present disclosure focuses on a chair for purposes of illustration, persons of ordinary skill in the art will readily recognize and appreciate that many other types of furniture pieces may be manufactured to include the principals described herein. Descriptions of particular embodiments (e.g., a chair, a table, a step, an Adirondack chair, a footrest, or the like) are merely exemplary and are in no way limiting. Appendix A, which is attached hereto and incorporated by reference, includes drawings that illustrate other exemplary components and fully assembled furniture pieces (e.g., chairs of various sizes and styles, a footrest, a table, and a step) that fall within the scope of the present disclosure. Each of the furniture pieces features one or more instances of the unique tension joint and/or unique rounded regions described above and provides all of the same benefits discussed in the context of the chair depicted in the preceding drawings. Any dimensions, materials, shapes, or configurations identified in Appendix A are merely exemplary and should in no way be construed as exhaustive or limited. Many other forms of furniture will readily suggest themselves to persons skilled in the art after viewing the present disclosure, including but not limited to benches, tables, shelves, planter boxes, beds, desks, and stools.
The above description is illustrative and not restrictive. Many variations of the furniture pieces described above for illustrative purposes will become apparent to those of skill in the art in view of the present disclosure. While the furniture pieces have been described in connection with a variety of embodiments, these descriptions are not intended to limit the scope of the present invention to the particular forms set forth herein. On the contrary, the present disclosure is intended to cover numerous alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims and otherwise appreciated by one of ordinary skill in the art.

Claims

What is claimed is:

1. A fastenerless and adhesiveless furniture piece, comprising:

a first panel, the first panel including a first edge, a second edge, a top surface disposed between the first edge and the second edge, a bottom surface disposed opposite the top surface between the first edge and the second edge, side edges each disposed between the first edge and the second edge, and an engagement member extending outwardly from each side edge, wherein the second edge includes a curve and each engagement member includes a tapered void;

a second panel, the second panel including a first edge, a second edge, a top surface disposed between the first edge and the second edge, a bottom surface disposed opposite the top surface between the first edge and the second edge, side edges each disposed between the first edge and the second edge, and an engagement member extending outwardly from each side edge, wherein the first edge includes a curve and each engagement member includes a tapered void; and

a plurality of support panels, each support panel including a first slot that mates with an engagement member of the first panel and a second slot that mates with an engagement member of the second panel, wherein the first panel, the second panel, and the plurality of support panels are securely coupled to form the furniture piece when the second edge of the first panel is forced into abutting engagement with the first edge of the second panel.

2. The furniture piece of claim 1, wherein the thickness of the support panel is less than an outer width of the tapered void of each engagement member and greater than an inner width of the tapered void of each engagement member.

3. The furniture piece of claim 2, wherein the forcing the second edge of the first panel into abutting engagement with the first edge of the second panel includes forcing each engagement member of the first panel into abutting engagement with a corresponding first slot of each support panel.

4. The furniture piece of claim 3, wherein forcing each engagement member of the first panel into abutting engagement with a corresponding first slot of each support panel includes forcing the support panel into the tapered void of the engagement member.

5. The furniture piece of claim 4, wherein forcing the support panel into the tapered void of the engagement member includes forcing the support panel through the outer width of the tapered void and into the inner width of the tapered void.

6. The furniture piece of claim 2, wherein the forcing the second edge of the first panel into abutting engagement with the first edge of the second panel includes forcing each engagement member of the second panel into abutting engagement with a corresponding second slot of each support panel.

7. The furniture piece of claim 6, wherein forcing each engagement member of the second panel into abutting engagement with a corresponding second slot of each support panel includes forcing the support panel into the tapered void of the engagement member.

8. The furniture piece of claim 7, wherein forcing the support panel into the tapered void of the engagement member includes forcing the support panel through the outer width of the tapered void and into the inner width of the tapered void.

9. The furniture piece of claim 1, wherein the curve of the second edge of the first panel is convex with respect to a center of the top surface of the first panel.

10. The furniture piece of claim 1, wherein the curve of the first edge of the second panel is concave with respect to a center of the top surface of the second panel.

11. The furniture piece of claim 1, securely coupling the first panel, the second panel, and the plurality of support panels to form the furniture piece includes two or fewer steps.

12. The furniture piece of claim 1, wherein the furniture piece includes four or fewer components.

13. The furniture piece of claim 1, wherein the plurality of support panels are identical.

14. The furniture piece of claim 1, wherein a uniform thickness of the first panel, the second panel, and the plurality of support panels are the same.

15. The furniture piece of claim 1, wherein the furniture piece is fastenerless.

16. The furniture piece of claim 1, wherein the furniture piece is adhesiveless.

17. The furniture piece of claim 1, wherein the furniture piece is a chair.

18. The furniture piece of claim 1, wherein the furniture piece is a step.

19. The furniture piece of claim 1, wherein the furniture piece is an adirondack chair.

20. The furniture piece of claim 1, wherein the furniture piece is a footrest.