The present invention relates in general to a modular furnishing system and modular components for building a variety of furniture items and in particular to a modular furnishing system and components of such a size, shape and design so as to be easily capable of making a large number and variety of sturdy, quality, standard furniture items from a small number of types of components.
Prior furniture modules have been attempted with limited success because of a lack of simplicity, yet versatility, of design and a lack of incorporation of a formula suitable for sizing a minimum combination of modules to achieve a maximum number of furniture combinations. Lacking in simplicity of design, these prior art furniture modules, when combined, have resulted in furniture combinations that have peculiar and distinctive design features that may not be appreciated by consumers.
There is lacking in the prior art a simple design, yet highly versatile, modular furnishing system that enables consumers to have the flexibility to create standard-sized desks, dining tables, work stations, coffee tables, entertainment centers, book shelves, bedroom sets, etc., all from a minimum number of modular furniture combination types. Prior art modular furnishing systems are unduly complex, and require complicated and widely varying types of attachment, combination and assembly mechanisms and procedures. Thus, rather than use prior art modular furnishing systems, consumers have been limited in their options of achieving easily derived, simple furnishing types, having instead been required to either buy custom-made furniture to suit the consumer's needs, or having been required to engage in unduly complex processes or designs to achieve sometimes standard, but many times non-standard, furniture combinations. This, in turn, has led to increased difficulty, frustration and expense associated with creating furniture from prior art modular furnishing components.
Further, owing to the more complex prior-art designs of modular furnishing component systems, there has been difficulty and added expense in manufacturing the prior art components. This complexity has also led to an increased need for warehouse space for increased inventory Stock Keeping Units (SKU) and increased numbers of parts. There is needed a simplified modular furnishing component system that is easily mass-manufactured into a quality modular furnishing component system.
In accordance with a first aspect of the present invention, there are provided a plurality of modular furnishing components that are of ideal size and simple in design and function so as to be used alone, or readily combined with other modular components, to form a wide variety of furnishing structure combinations, including but not limited to a desk, base for a bed, dining table, coffee table, workstation, entertainment center, book shelf, window seat, hutch, cabinet, dresser, chest or closet organizer, all from a minimum number of furnishing components.
Each modular furnishing component provided in accordance with the first aspect of the present invention comprises a plurality of structural cross members, preferably made of wood frame members joined at the corners and interfaces by dowel and/or tongue and groove construction techniques, or other commonly known joining means, to form a cuboidal (3-d Square-Faced Cube) or paralleliped (3-d Rectangular-Faced Box) frame. The modular furnishing component also preferably includes an upper and/or a lower planar, rectangular-shaped, surface member having four corners. Each corner of the upper surface member is aligned with an adjacent corner of the lower surface member, with each corner being connected to its corresponding other surface member corner by L-shaped (in cross-section) stiles, or vertically oriented frame or cross members. In one embodiment of the invention the component is open, with only the structural frame members interconnecting the upper and lower surfaces at the corners.
Preferably, there are horizontally oriented rails or frame members which interconnect the vertically oriented stiles or frame members and extend lengthwise adjacent an inner surface of and around the perimeter of each upper and lower planar surface, to lend rigidity and strength to the component.
While the invention is most basically comprised of two modular component sizes (the first and third components listed below), there are preferably four basic modular component sizes in the preferred embodiment of the invention, first, a cube-shaped, modular furnishing component that is about 18×about 18×about 18 inches in dimension (x, y, z coordinates), second, a cube-shaped, modular furnishing component that is about 9×about 9×about 9 inches in dimension, third, a rectangular box-shaped modular furnishing component that is about 18×about 9×about 9 inches in dimension, and fourth, a rectangular box-shaped modular furnishing component that is about 18×about 9×about 18 inches in dimension. In accordance with this first aspect of the invention, the cross members and any surface members are preferably appropriately sized so that when combined together to form the modular furnishing component, the overall modular furnishing component is of the preferred dimensions described above to readily be combinable to form furnishing elements of standard dimensions.
In accordance with another aspect of the invention there are provided cut lists and process engineering drawings to enable easy, cost-effective, mass production of modular furnishing components. The cut lists provide the data to create modular furnishing components of the size and shapes described specifically above. These data are appropriately expressed as a formula herein so as to allow creation of varying dimensions of standardsized modular furnishing components.
In accordance with another aspect of the invention there are provided multiple uniform family of accessories for completing desired furniture designs with the aforementioned size combination modular furnishing components, including fixed cover panels and decorative inserts (square and rectangular of different styles), hinged door panels, rolling drawer insert units (for cube and rectangle components), roller platforms, spin platforms, square and rectangular shelves, table, desk top, and other plank tops.
In accordance with yet another aspect of the invention, there are a series of holes pre-drilled on the inside of each modular furnishing component allowing for installation of pegs for installing shelving within the modular furnishing component at varying levels. The holes are pre-drilled along different axes of the cube so that a shelf or other divider may be installed regardless of the orientation of the cube.
The modular components of the invention are mixed, combined, matched, stacked, and oriented relative to each other to formulate varying furnishing combinations. The components are sized appropriately such that simple combinations of the components, or the components alone, form standard-sized furnishing in accordance with commonly known building code sizes. For example, an 18 inch cube-shaped component with a 9 inch rectangular box-shaped component stacked thereon forms a standard base for a standard-sized 27-inch high desk top. As another example, a standard 36-inch high countertop is easily accommodated with two 18-inch high modular furnishing components.
Thus, the invention comprises pre-manufactured and pre-drilled cube-shaped and rectangle box-shaped frame components appropriately sized so as to form standard-sized furnishings with a minimum number of interchangeable components, each component providing the end-user multiple accessory options for each component so as to give maximum flexibility for function, storage, filing and design of resulting furnishings made with the components.
The modular furnishing frame components are preferably made of rubber wood, but are suitably made of any rigid standard building material, including but not limited to other hard woods, metal or plastic.
Another aspect of the invention includes connector brackets. An “S-shaped” cross-section bracket is conveniently used to mount a cube to the wall by screwing the bracket into the wall with an upright portion of the bracket pointing upwardly and outwardly from the wall to form a slot between the bracket and the wall, slipping the back upper portion of the frame portion of a cube-shaped or rectangular modular furnishing frame component into the resulting slot between the bracket and the wall, and securing the module to the bracket with one or more wood screws if desired.
Two modular furnishing frame components may be connected, for example to form a coffee table, by using a “U-shaped” cross section bracket to interconnect the upper inner frame portions of each component. Alternatively, two “S-shaped” brackets can be connected lengthwise together to form a “goal-post-shaped” bracket to form a “U-shaped” bracket (the upright portion of the “goal posts”) to connect two modular furnishing frame components together.
The brackets of the invention allow other standard furniture sizes, such as a 30-inch dining table top accommodated with an 18-inch high modular furnishing component having a 9-inch high modular furnishing component stacked thereon, or underneath, and a 3-inch bracket to raise the table top to the desired standard height. The formula of the present invention is disclosed and claimed which allows the creation of any standard sized furniture from a minimum overall number of modular components.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following descriptions taken in connection with accompanying drawings wherein like reference characters refer to like elements.
Referring to
Referring to
Returning to
Preferably the standard cube-shaped modular furnishing component 20 is of a standard outside dimension size of about 18×about 18×about 18 inches (x, y, z coordinates). However, it will be appreciated that other standard sizes of a cube may be employed without departing from the true scope and spirit of the invention.
To construct the cube-shaped modular furnishing component 20, two vertical support frame members (or stiles) 24 and upper and lower horizontal support frame members (or rails) 25 may be formed into a rectangular frame. Four such square frames may be combined using a construction method further described in this disclosure or any method otherwise commonly known in the industry to form the frame of the cube-shaped modular furnishing component 20. For example, mortise and tenon, English dovetailing, tongue and groove, or dowel and groove construction methods can be employed to join the various pieces to form furnishing component 20. After the four square frames are joined to form a cube-shaped frame, an upper surface 22 and/or a lower surface 26 are preferably added. Alternatively, corners of the cube-shaped modular furnishing component 20 may be first constructed with vertical support frame members 24.
Under this embodiment, the various components for constructing component 20 number in quantity, and are approximately sized (width, length, thickness in inches), as follows: one upper surface 22 sized about 18×about 18×about ¾ inches; one lower surface 26 sized about 18 inches×about 18 inches×about ¾ inches; four bottom (partially shown in
Referring to
Preferably the standard cube-shaped modular furnishing component 30 is of a standard size of about 9×about 9×about 9 inches (x, y, z coordinates). However, it will be appreciated that other sizes of a cube may be employed without departing from the true scope and spirit of the invention. Component 30 is characterized in that the perimeter of each of the six sides comprising the cube-shape design is square in shape.
To construct the cube-shaped modular furnishing component 30, two vertical support frame members (or stiles) 34 and upper and lower horizontal support frame members (or rails) 35 may be formed into a square frame. Four such square frames may be combined using a construction method further described in this disclosure or any method otherwise commonly known in the industry to form the frame of the cube-shaped modular furnishing component 30. For example, mortise and tenon, English dovetailing, tongue and groove, or dowel and groove construction methods can be employed to join the various pieces to form furnishing component 30. After the four square frames are joined to form a cube-shaped frame, an upper surface 32 and/or a lower surface 36 are preferably added. Alternatively, corners of the cube-shaped modular furnishing component 30 may be first constructed with vertical support frame members 34.
Under this embodiment, the various components for constructing component 30 number in quantity, and are approximately sized (width, length, thickness in inches), as follows: one upper surface 32 sized about 9×about 9×about ¾ inches; one lower surface 36 sized about 9 inches×about 9 inches×about ¾ inches; four bottom (partially shown in
Referring to
Preferably the standard rectangular box-shaped modular furnishing component 40 is of a standard size of about 18×about 9×about 9 inches (x, y, z coordinates). However, it will be appreciated that other standard sizes may be employed without departing from the true scope and spirit of the invention. Component 40 is characterized in that the perimeter of each of the four sides comprising the sides of the rectangular box-shape design is rectangular in shape with lengths of each rectangle perimeter being longer than the heights thereof, and further is characterized in that the perimeter of each of the two ends of the rectangular box-shaped design is square in shape.
To construct the rectangular box-shaped modular furnishing component 40, two vertical support frame members (or stiles) 44 and upper and lower horizontal support frame members (or rails) 45 may be formed into a rectangular 40 frame. Two such rectangular frames are used. Further, two vertical support frame members 44 and upper and lower horizontal support frame members 47 (shorter rails) may be formed into a square frame. Two such square frames are also used. The two square frames are joined with the two rectangular frames, with one square frame at each end of the rectangular frames using a construction method further described in this disclosure or any method otherwise commonly known in the industry to form the frame of the rectangular box-shaped modular furnishing component 40. For example, mortise and tenon, English dovetailing, tongue and groove, or dowel and groove construction methods can be employed to join the various pieces to form furnishing component 40. After the frames are joined to form a rectangular box shaped frame, an upper surface 42 and/or a lower surface 46 are preferably added. Alternatively, corners of the rectangular box-shaped modular furnishing component 40 may be first constructed with vertical support frame members 44.
Under this embodiment, the various components for constructing component 40 number in quantity, and are approximately sized (width, length, thickness in inches), as follows: one upper surface 42 sized about 9×about 18×about 23/32 inches; one lower surface 46 sized about 9 inches×about 18 inches×about 23/32 inches; two bottom (partially shown in
Referring to
Preferably the standard rectangular box-shaped modular furnishing component 50 is of a standard size of about 18×about 9×about 18 inches (x, y, z coordinates). However, it will be appreciated that any other sizes or shapes may be employed without departing from the true scope and spirit of the invention. Component 50 is characterized in that the perimeter of each of the four sides comprising the sides of the rectangular box-shape design is rectangular in shape with lengths of the rectangle being longer than the heights hereof, and further is characterized in that the perimeter of each of the two upper and lower surfaces comprising the rectangular box-shaped design is square in shape.
To construct the rectangular box-shaped modular furnishing component 50, two vertical support frame members (or stiles) 54 and upper and lower horizontal support frame members (or rails) 55 may be formed into a rectangular frame. Four such rectangular frames may be combined using a construction method further described in this disclosure or any method otherwise commonly known in the industry to form the frame of the rectangular box-shaped modular furnishing component 50. For example, mortise and tenon, English dovetailing, tongue and groove, or dowel and groove construction methods can be employed to join the various pieces to form furnishing component 50. After the four rectangular frames are joined to form a rectangular box-shaped frame, an upper surface 52 and/or a lower surface 56 are preferably added. Alternatively, corners of the component 50 may be first constructed with vertical support frame members 54.
Under this embodiment, the various components for constructing component 50 number in quantity, and are approximately sized (width, length, thickness in inches), as follows: one upper surface 52 sized about 18×about 18×about 23/32 inches; one lower surface 56 sized about 18 inches×about 18 inches×about 23/32 inches; four bottom (partially shown in
Referring to
The square base frame member 62 is sized appropriately so as to fit within a bottom portion of cube-shaped modular furnishing component 20. Once the frame member 62 with drawer guides 61 is located in the bottom portion of cube-shaped modular furnishing component 20, a plurality of wood screws are preferably placed in the frame member 62 to screw the frame member to lower horizontal frame components 25 or lower surface 26 of cube-shaped modular furnishing component 20. After installation of the base frame member 62 with drawer guides 61, file drawer 60 can be placed for sliding movement along the drawer guides within modular furnishing component 20.
In this fashion, a file drawer 60 may be located in any area of a piece of furniture where there is located a modular furnishing component 20. Thus, for example as shown in
Modular furnishing component 40 also has a file drawer 64 therein. As shown in
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As shown in
Holes 77, 78 are provided in the first and second protrusion sections or members for allowing passing through of a plurality of wood screws or nuts and bolts to interconnect the brackets and frame members as described herein. In some embodiments, the middle section and the first protruding member define a first space or area and the middle section and the second protruding member define a second space or area. In some embodiments, the first and second space or area are sized to fit any of horizontal members 25, 35, 45, and 55. In some embodiments, the first and second areas may be sized to fit other components of the modular furniture system, and the first and second areas may each be configured or sized the same or differently.
The left pane of
The right panel of
Bracket 75 may sized as necessary to secure together the various features above. For example, bracket 75 may create a space of just over about ¾ inches between the wall and a protruding portion of bracket 75 to allow for the about ¾ inch thickness portion of any of the above vertical or horizontal frame members to fit inside the space to secure the fitted frame member to the wall. In some embodiments, the length of the middle section to a distal end of the first protruding section may be about 1⅛ inches, and to a distal end of the second protruding section may be about 1⅛ inches. Each corner of the distal end of the first and second protruding section may be rounded. Each rounded corner may have a radius of about ½ inch.
From bottom to top,
U-shaped brackets 72, 74 can be sized to secure together adjoining modular components. For example,
Alternatively, U-shaped bracket 74 may also be formed by combining two S-shaped (cross section) brackets 73, 75 lengthwise, with a plurality of bolts 76 to form the “goal-post”-shaped, U-shaped bracket 74. U-shaped bracket 74 may then be used in the same way as U-shaped bracket 72 to combine two horizontal frame members 25 of cube-shaped modular furnishing components 20. Further, U-shaped brackets 72 (and/or 74) may be used to interconnect adjacently positioned horizontal frame members 25, 35, 45, and/or 55, of modular furnishing components 20, 30, 40 and/or 50, respectively, or any combination of these, to allow for a wide variety of connections of modular furnishing components to create various furniture designs. In fact, brackets 72, 74, 75, and 79 can each be used in the same manner as described herein in association with one of the other brackets. It will be appreciated that U-shaped brackets 72, 74 may sized as necessary to secure together the various features above.
It will be appreciated by those of ordinary skill in the art that varying lengths of the above described brackets may be incorporated to interconnect furnishing modules, connect a module or modules to the wall, or to interconnect other furnishing components, such as plank tops, to furnishing modules. It will also be appreciated that other types of connectors can be employed, such as double-sided tape or dowels, to interconnect a modular component with other components or with accessories, or to connect a modular component to a wall. In some embodiments, modular components, accessories, etc. will not be interconnected at all, but will be attached, adjoining, or stacked without any connector connecting them together.
Referring to
Another accessory, a spinning platform 93, for the modular furnishing component system of the invention is shown in
As shown in
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Referring to
In other embodiments, the system may be configured as an “L-Shaped” corner desk made of three cube-shaped modular furnishing components 20A-20C, two rectangular box-shaped modular furnishing components 40A-40B, and one rectangular box-shaped modular furnishing component 50. The surface of the “L-Shaped” corner desk can be comprised of two plank members 66. Rectangular box-shaped furnishing component 40A can have a drawer 64 therein. Each of two cube-shaped modular furnishing components 20A and 20C can have drawers 60 therein. Other flat panel surfaces 21 are employed for decorative and finishing effect.
In other embodiments, the system may be configured as a set 110 of dining table and chairs made from two cube-shaped modular furnishing components 20 oriented diagonally adjacent and relative to each other on the floor, each component 20 having diagonally stacked thereon two rectangular boxshaped modular furnishing components 40, all components 20 and 40 being preferably of standard height. Accordingly, the heights of components 20 and 40, combined, add up to a standard table top height of 27 inches (component 20 preferably being 18 inches tall and component 40 preferably being 9 inches tall). One or more plank tops 66 rest upon, and are preferably attached to, components 40, which are in turn attached to their respective components 20, as with brackets, in order to form a solid dining table. The height of the resulting dining table 112 is convenient to allowing persons to sit at the table using standard modular furnishing components 20 as benches or chairs. The components 20 are very sturdy and thus withstand the repeating stresses of persons sitting on them.
In other embodiments, a modular furnishing system comprises at least two standard-sized, uniform components able to be combined to form a plurality of standard-sized furniture items comprising: an open-sided, cube-shaped cuboidal component, said cube-shaped component having a horizontally planar, upper square surface having four corners, said cube-shaped component also having a horizontally planar, lower planar surface having four corners, said corners of said upper surface being aligned with corresponding corners of said lower surface, and each said lower surface corner being interconnected to each said corresponding upper surface corner with at least one stile frame member; and an open-sided, rectangular box-shaped paralelliped component, said rectangular box-shaped component having a horizontally planar, upper rectangular surface having four corners, said rectangular box-shaped component also having a horizontally planar, lower planar surface having four corners, said corners of said upper surface being aligned with corresponding corners of said lower surface, and each said lower surface corner being interconnected to each said corresponding upper surface corner with at least one stile frame member; wherein said cube-shaped component and said rectangular box-shaped component are able to be stacked to form a standard-sized furnishing element. In some embodiments, the modular furnishing components of this paragraph comprise a desk.
In some embodiments, a modular furniture system and components and furniture built using the same comprise at least one open-sided, cube-shaped cuboidal component further comprising structural stile frame members, rail frame members, an upper planar surface and a lower planar surface to form the cuboidal component and at least one open-sided, rectangular box-shaped paralelliped component further comprising structural stile frame members, rail frame members, an upper planar surface and a lower planar surface to form the rectangular box-shaped component. The open-sided cube-shaped component and the open sided box-shaped paralelliped component are readily combinable to form a plurality of standard-sized furniture items with a minimal number of modular components.
The present invention may also comprise processes for cutting, with a table saw, a planer device or other suitable machine, as will be understood by those of ordinary skill in the art upon being presented with the part dimensions, such as those listed above for
The aforementioned cut lists also reduce to a minimum the types of cuts required for the various parts disclosed. It will be appreciated by those of ordinary skill in the art that other standard size dimensions may be accommodated with similar cut lists according to a formula that expresses the dimension in terms of fractions of the standard size. Preferably, a formula for generating cut lists for standard-sized components is expressed as follows:
Cutting of stiles, rails and planar surfaces for a cube-shaped modular component 20 to thickness, width and length dimensions according to the following numbers of parts: 2×planar surface members, 8×rail members, 4×stile members (size 1), and 4×stile members (size 2), wherein all stiles, rails and planar surface members are of a thickness= 1/24×standard; wherein each planar surface member is of a length=1×standard and a width of 1×standard; wherein all stile lengths= 91.67/100×standard, all stile widths (size 1)= 1/9×standard; all stile widths (size 2)= 1/14.4×standard; wherein all rail widths= 1/14.4×standard; and wherein all rail lengths= 77.7/100×standard. In the aforementioned formula, it is assumed that the standard dimension is equal in each of the x, y and z dimension directions. When constructing a modular component 20 with dimensions of about 18×about 18×about 18 inches (x, y, z coordinates) is desired, applying the above formula may yield the parts sizes listed above in association with
Cutting of stiles, rails and planar surfaces for a cube-shaped modular component 30 to thickness, width and length dimensions according to the following numbers of parts: 2×planar surface members, 8×rail members, 4×stile members (size 1), and 4×stile members (size 2), wherein all stiles, rails and planar surface members are of a thickness= 1/12×standard; wherein each planar surface member is of a length=1×standard and a width of 1×standard; wherein all stile lengths= 84.03/100×standard, all stile widths (size 1)= 22.2/100×standard; all stile widths (size 2)= 13.89/100×standard; wherein all rail widths= 13.89/100×standard; and wherein all rail lengths= 5/9×standard. In the aforementioned formula, it is assumed that the standard 20 dimension is equal in each of the x, y and z dimension directions. When constructing a modular component 30 with dimensions of about 9×about 9×about 9 inches (x, y, z coordinates) is desired, applying the above formula may yield the parts sizes listed above in association with
Cutting of stiles, rails and planar surfaces for a rectangular box-shaped modular component 40 to thickness, width and length dimensions according to the following numbers of parts: 2×planar surface members, 4×rail members (size 1), 4×rail members (size 2), 4×stile members (size 1), and 4×stile members (size 2), wherein all stiles and rails are cut to a thickness of 1/24th of the x-dimension standard, and wherein all planar surface members are cut to a thickness of 1/25.04× the x-dimension standard; wherein each planar surface member is of a length=1×the x-dimension standard and a width of 1×the y-dimension standard; wherein all stile lengths= 84.03/100×the y dimension standard, all stile widths (size 1)= 22.2/100×the z-dimension standard; all stile widths (size 2)= 13.89/100×the z-dimension standard; wherein all rail widths= 13.89/100×the z-dimension standard; wherein all rail lengths (size 1)= 77.7/100×the x-dimension standard, and wherein all rail lengths (size 2)= 5/9×the z-dimension standard. In the aforementioned formula, it is assumed that the standard dimension may be different for each the x, y and z-dimension directions, though preferably, the y and z dimension directions are equal. When constructing a modular component 40 with dimensions of about 18×about 9×about 9 inches (x, y, z coordinates) is desired, applying the above formula may yield the parts sizes listed above in association with
Cutting of stiles, rails and planar surfaces for a rectangular box-shaped modular component 50 to thickness, width and length dimensions according to the following numbers of parts: 2×planar surface members, 8×rail members, 4×stile members (size 1), and 4×stile members (size 2), wherein all stiles and rails are cut to a thickness of 1/24×the x-dimension standard, and all planar surface members are cut to a thickness of 1/25.04×the x-dimension standard; wherein each planar surface member is of a length=1×the x-dimension standard and a width of 1×the y-dimension standard; wherein all stile lengths= 84.03/100×the y-dimension standard, all stile widths (size 1)= 1/9×the x-dimension standard; all stile widths (size 2)= 1/14.4×the x-dimension standard; wherein all rail widths= 1/14.4×the x-dimension standard; and wherein all rail lengths= 77.7/100×the x-dimension standard. In the aforementioned formula, it is assumed that the standard dimension may be different for each the x, y and z-dimension directions, though preferably, the x and z-dimension directions are equal. When constructing a modular component 50 with dimensions of about 18×about 9×about 18 inches (x, y, z coordinates) is desired, applying the above formula may yield the parts sizes listed above in association with
As a result of these formulas, a minimum number of parts (rails, stiles and planar tops and bottoms—the latter two of which are preferably the same for each component) may be stored with a minimum amount of inventory allowing for a minimum amount of warehouse space. This is accomplished, in part, in that the invention provides a minimum number of sizes and types of uniform rails, as a stock of parts, able to be used in each component. This is also accomplished, in part, in that the invention provides a minimum number of sizes and types of uniform styles, as a stock of parts, able to be used in each component. Also, in accordance with the invention, there is disclosed a modular furnishing component system that allows for a minimum number of components to create a maximum number of standard-sized furniture types. Thus, there is accomplished the objective of ability to build a maximum number of standard-sized furnishing combinations from storage of a minimum number of Stock Keeping Units (SKUs) (modular furnishing components). This in turns allows an effective number of SKUs to be stored in a smaller warehouse.
After the process of cutting the parts to appropriate sizes for each of the modular furnishing components, a process is provided preferably comprising the steps of notching, boring and grooving each of the parts together. A plurality of bore holes are provided in each of the stiles, rails and planar surface members to enable interconnecting these parts with the use of a plurality of dowels, one dowel for each matching and adjacent set of bore holes in facing rails/planar surface members, rails/size 1 stiles, rails/size 2 stiles, and size 1/size 2 stiles.
Grooves are cut in each of the stiles and rails for appearance purposes to give the appearance that there is only one size of stiles and the appearance of continuity of rail grooves around the entire module. Each size 1 stile is joined along its length with dowel construction to, and along the length of, a corresponding size 2 stile, each such pair of 5 stiles being joined to form a corner of the module. Four such corners of the module, each comprising a size 1 and a size 2 stile, are interconnected at a top and a bottom area of each corner, by upper and lower rails extending in each direction at 90-degree angles to each adjacent rail of the same type (upper or lower), and so on, until a cube-shaped, or rectangular box-shaped frame is formed. After each such cube-shaped, or rectangular box-shaped frame is thus formed, each frame is topped with a planar surface member and bottomed with a planar surface member, each such planar surface member being joined to the upper and lower rails, respectively, via a dowel interconnecting each adjacent bored hole in the rails and planar surface members. Wood glue is suitably employed in each bore and dowel joint to hold the joint firmly in place. It will be appreciated that the stiles and rails can also be attached by any other appropriate construction method, including the ones disclosed herein.
In some embodiments, a process of cutting wood to appropriately-sized parts for modular furnishing components comprises the steps of cutting rails, stiles and planar surface areas according to a formula for creating a uniform cube-shaped module having equal standard dimensions in each of x, y and z dimensions, said formula for cutting stiles comprising cutting all rails, stiles and planar surface areas to a thickness of 1/24 of one of said standard dimensions, cutting a plurality of planar surfaces areas to a width of 1×one of said standard dimensions and a length of 1×one of said standard dimensions, cutting a plurality of first stiles to a width of 1/9 of one of said standard dimensions, cutting a plurality of second stiles to a width of 1/14.4 of one of said standard dimensions, cutting each of said first stiles and each of said second stiles to a length of 91.67/100 of one of said standard dimensions, and cutting a plurality of rails to a width of 1/14.4 of one of said standard dimensions and a length of 77.7/100 of one of said standard dimensions.
While a preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/144,618 entitled “MODULAR FURNISHING SYSTEM AND COMPONENTS AND FURNITURE BUILT USING THEM,” filed Jan. 14, 2009, the complete disclosure of which is hereby incorporated by reference for all purposes.
Number | Date | Country | |
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61144618 | Jan 2009 | US |