WO1994010462A1

WO1994010462A1 - Foldable frame with self-locking mechanism

Info

Publication number: WO1994010462A1
Application number: PCT/US1993/010651
Authority: WO
Inventors: Dan O'sullivan; Craig A. Mengel
Original assignee: Tandy Corporation
Priority date: 1992-11-05
Filing date: 1993-11-05
Publication date: 1994-05-11

Abstract

A foldable frame, defined by a board having a first end, a second end and a permanently attached covering, with mitered joints cut at selected positions through the board but not through the covering, and having a hook and loop attachment mechanism, is disclosed. The hook and loop attachment mechanism, commonly known as VelcroR, allows a foldable frame to be constructed using mitered joints, for allowing quick assembly in ready to assemble furniture.

Description

FOLDABLE FRAME WITH SELF-LOCKING MECHANISM

BACKGROUND OF INVENTION This invention relates generally to ready to assemble furniture. More specifically, this invention relates to a foldable frame structure that has self-locking devices at the edges where the fold closes. Ready to assemble (RTA) furniture is well known in the art. One feature found in RTA furniture is the use of mitered cuts to provide folding frame structures. To make a folding frame using mitered cuts, a single plank of wood or particle board is covered with either vinyl or paper and then is miter cut, at an angle of approximately 45 degrees on each side, through the width of the board, but not through the thickness of the covering on one side. This 45 degree cut on each side forms a 90 degree angle about which the frame can be folded. The covering provides continued connection between the otherwise separate board elements.

Three miter cuts at selected positions allow a single board to fold into a four-sided, box or rectangular frame. The free ends of the box are joined together by such means as applying glue to both ends and pressing them together with clamps until the glue cures. Another means is to use screws to join the two ends together. Yet another means is to use dowels, which hold the ends together, and then glue the surfaces together. The dowels also strengthen the joint. Yet another method is to miter both corners at an angle and then glue the corners together.

One desire in RTA furniture is that it be quick and easy to assemble, without added mess or the need for tools. Unfortunately, the use of these assorted attachment techniques, such as the glue, the screws, or the dowels, require additional time, effort, and tools from the user to assemble the furniture. Furthermore, with frame material such as particle board, glues can deteriorate, screws can strip and dowels can loosen, thus weakening the joint. Due to the above limitations of the current methods used to build folding frames for use in RTA furniture, what is needed is a new attachment mechanism that is quick to attach without the mess of glues or screws, or the need for tools, allows quick alignment and is at least as durable as those currently available.

SUMMARY OF INVENTION According to the present invention, a foldable frame having a first end and a second end and hook and loop attachment mechanism is disclosed. The foldable frame is made from a length of board having a first end, a second end and a permanently attached covering. The board has mitered joints cut as selected positions (preferably three), which cuts pass through the board but not through the covering. A hook attachment mechanism is mounted .on the first end of the board and a loop attachment mechanism is mounted to the second end of the board. This hook and loop mechanism allows the frame to fold about the mitered joints and attach together. The foldable frame is further characterized by including alignment guides, such as dowels or screws, which are mounted on the first end of the board and alignment receptors, which are mounted on the second end of the board and which receptors are for receiving the alignment guides . The mitered joints may be secured with a permanent bond, such as, for example, glue or screws.

The foldable frame can also be made from selected boards mitered on each end and then attached together with an attaching cover. The attaching cover is also flexible to allow the miter joints to fold in proper alignment. The joints may be permanently secured with any suitable bonding means.

The hook and loop attachment mechanism is commonly known as Velcro. The hook and attachment mechanism may be further defined such that the hook attachment mechanism mounts on with a first portion on one end of the board and a second portion on the second end of the board, with the loop attachment mechanism extending both portions to attach the free ends together. This foldable frame is the basis for many types of furniture found in the ready to assemble furniture arts. Several examples are detailed below:

The foldable frame may include an attached bottom shelf, thus providing a box with a bottom support. A handle may be mounted to one of the exterior surfaces of the sides, thereby defining a drawer with a handle. Side runners may be mounted on two opposing sides to allow the drawer to fit slidably into a cabinet. A bookcase is further contemplated in the present invention by adding to the frame at least one or two support shelves, which may be mounted between a first side and a second side with the same hook and loop attachment mechanism, or with pegs on which the shelf may rest. This shelf may be further modified to be deeper in size and to have closing doors and a back enclosure, thus forming a cabinet with shelves. Drawers may be added to the cabinet to form an armoire.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 illustrates a board having three mitered cuts and hook and loop attachments mounted at opposite ends to allow the board to fold into a four sided frame;

Fig. 2 illustrates the folds about the three mitered cuts with the attachment at the opposite ends of the board of Fig. 1;

Fig. 3 illustrates a top plan view of a four- sided frame according to the present invention;

Fig. 4 shows side views of the hook and loop attachments used at the ends of the frame of Fig. 1;

Fig. 5 shows a drawer using the folding frame according to the present invention;

Fig. 6 shows a bookshelf using the folding frame according to the present invention; Fig. 7 shows an armoire cabinet using the folding frame according to the present invention;

Fig. 8 shows a triangularly-shaped folding frame according to the present invention;

Fig. 9 illustrates an octagonal shape frame using the edge attachment means of the present invention;

Fig. 10 illustrates a way of recessing the hook and loop material on the ends to provide a flush joint between the opposite ends of the frame on attachment;

Fig. 11 illustrates a hook and loop mechanism having self-guiding elements; and

Fig. 12 illustrates a foldable frame using hook and loop mechanism on the outside surfaces of the free ends of the frame.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Fig. 1 shows a foldable frame 10, which is made of any suitable material such as, for example, wood, particle board, plywood, styrofoam, or any other type of material typically used in the construction of ready to assemble (RTA) furniture. Frame 10 is covered with a suitable covering, such as paper, vinyl, fabric, paint, laminate, melamine, or veneer, which is flexible and resists tearing. The covering may be on one or both sides of the frame and serves as a hinge when the frame is miter cut. The cut is completely through the frame material, but not through the covering. This allows the cut pieces to remain attached together, but also allows foldability because of the flexibility of the covering. Frame 10 includes three separate mitered joints

12, which are angled at about 45 degrees to the surface of frame 10 to provide three right angled joints in frame 10 when folded. Mitered joints 12 divide frame 10 into four sides, side 14, side 16, side 18, and side 20, with their lengths being determined by the position of each joint. Sides 14 and 20 are designed to attach to one another, thus closing the frame. Rather than using the traditional glue, dowels or screws, or any combination thereof, sides 14 and 20 include loop 22 and hook 24, which attach to each other. In an alternative embodiment, selected lengths of board are mitered cut on each end and then attached together end to end with a suitable attaching means, such as tape or any of the covering materials listed above. The attaching means is flexible enough to allow the boards to fold together, thus forming a frame. The free ends of the frame need not be mitered cut, but maybe left perpendicular to the board surface.

Loop 22 is attached to the face of side 14, while hook 24 is attached to the edge of side 20. For the most durable bond upon attachment, strips of loop 22 and hook 24 extend the full width of frame 10. If detachment is desired, or a less secure bond needed, loop 22 and hook 24 may be of varying strengths or lengths, which are not completely contiguous of the width of frame 10.

Loop 22 and hook 24 may be attached to frame 10 by any suitable adhesive such as, for example, with a urethane glue manufactured by Bostick, Model No. 9601, which is preferred when attaching the strips to particle board or paper covered particle board. Other adhesives may be suitable for applying the loop and hook mechanism to the particular frame material. Loop 22 and hook 24 are made of any suitable hook and loop material, the preferred being Velcro, which is manufactured by Velcro U.S.A., Inc. As stated above mitered joints 12 allow for sides

14, 16, 18, and 20 to wrap around each other to form a rectangular frame. Fig. 2 illustrates how each joint 12 allows the various sides to bend and form right angles with one another. Side 14 closes to contact with side 20, which attach by loop 22 and hook 24.

Fig. 3 illustrates a completed and closed frame 10 according to the present invention. Hook 24 and loop 22 attach to form a secure bond with one another and is rather durable once it is formed. This bond is achieved without the need of glues or screws, or additional tools.

Because of the mitered joints 12, the sides are self-guiding to urge the ends of side 12 and side 20 together in a congruous position. To provide a more precise alignment of the edges of side 12 and side 20, guides 26 are inserted in the edge of side 20, as shown in Fig. 4. Holes 28 for receiving guides 26 are formed in the face of side 14. Guides 26 may be such items as, for example, dowels, screws, camlocks, or any other similar element, which may fit loosely or snugly. For short widths of frame 10, a single guide 26 and hole 28 are sufficient. For longer lengths, more than two guides 26 and holes 28 may be used for alignment precision. It should be further understood that guides 26 may be formed by machining the edge of hook 24 to leave a guide.

The folding frame is a fundamental element in the construction of RTA furniture. For example, a frame is used to make drawers, bookshelves, cabinets, bed frames, and other pieces using a four-sided (or multi-sided) frame. A few examples, such as a drawer, a bookshelf, and an armoire cabinet, are described below and illustrated in the drawings.

Fig. 5 shows a drawer using frame 10 according to the present invention. The drawer includes sides 14, 16, 18 and 20, which are attached in a rectangular shape via loop 22 and hook 24. The drawer further includes a bottom 30, which may be of any suitable material, such as, for example, pressboard, particle board or plywood, which fits into grooves (not shown) cut into a bottom edge of the inside face of each of sides 14, 16, 18 and 20. In an alternative embodiment, bottom 30 may be attached using additional hook and loop material (Velcro), or may be -tached with glue, nails, or screws. The drawer is finished by adding handles 32 to the face of the drawer. Additional side runners 34 are attached to the outside surfaces of sides 14 and 18, which runners allow the drawer to slide easily in and out of the drawer cabinet, such as that shown in Fig. 7. Runners 34 may also be attached to the bottom of sides 14 and 18 by either clip-on slide, screws, nails, or other such fastener means.

Fig. 6 illustrates a bookshelf using the folding frame according to the present invention. The bookshelf has a first side 60, a bottom shelf 62, a second side 64, and a top shelf 66. Mitered cuts 12 are provided to serve as the joints at various corner locations. Loop 22 and hook 24 are added to the edge and face of sides 66 and 60, respectively, to provide closure of the bookshelf frame during assembly. Additional shelves 68 are provided, which are securely held in place by hook 24 and loop 22. Shelves 68 may also be supported by pegs 69 instead of hook 24 and loop 22.

Fig. 7 shows yet another embodiment in which frame 10 can be used. Fig. 7 shows an armoire having cabinet doors and drawers fitted to the frame. The armoire includes first side 70, bottom 72, second side 74 and top shelf 76. Hook 24 and loop 22 are used to complete the frame. Drawers 78 are adapted to fit into the frame completed by sides 70, 72, 74 and 76. Doors 80 are attached to sides 70 and 74 via hinges to allow the doors to enclose the interior of the frame. A back element 82 is provided to enclose the interior of the frame. Back element 82 may be attached using hook 24 and loop 22, nails, glue, screws, or camlocks. Finally, a shelf 84 is ^■ provided to protect the interior surface of drawer 78 while also providing a place to put additional objects inside the interior of the armoire. Shelves such as those in the bookcase of Fig. 6, may be added to provide storage support, or a closet rod (not shown) may be added so hangered clothes may be stored in the armoire.

Figs. 8 and 9 illustrate additional frames having different geometric construction that can be made using the mitered cuts and the hook and loop attachments according to the present invention. Fig. 8 illustrates a triangular folding frame having sides 86, 87, and 88, which are joined via mitered joints 89. Hook 24 and loop 22 are attached to the face and end of sides 86 and 88, respectively, to enclose the frame. Fig. 9 illustrates an octagonal frame having sides 90, 94, and 92. Sides 90 and 92 attach by loop 22 and hook 24 being attached to their respective face and edge. The illustration of the triangular frame in Fig. 8 and the octagonal folding frame in Fig. 9 show that the frame is not limited to a four-sided box or rectangle as shown in Fig. 3. Rather, any type of frame using mitered joints 12 may be obtained by adjusting the angle of the cut as well as the number of cuts in the length of the board.

The hook 24 and loop 22 need not mount on the face or edge of the particular side element. Rather, depressions may be grooved into the side elements to receive the hook and loop attachments as illustrated in Fig. 10. Side 100 shows a cutaway view of a groove 104 that receives loop 108. Side 102 is shown with a groove 106 that receives hook 110. This recess feature for loop 108 and hook 110 allows each to be flush with the side surfaces when attached to each other, thus hiding the use of the Velcro.

Fig. 11 illustrates the use of a Velcro attachment having self guiding elements to aid in alignment during assembly. Fig. 11 shows a hook strip 112, which mates with loop strip 114. Hook strip 112 includes guides 116, and loop strip 114 includes holes 118, which receive guides 116. Guides 116 are formed during the fabrication of hook strip 112. Holes 118 may or may not be included in strip 114 during fabrication. If they are not included initially, they may be added later when holes are drilled through the strip 114 after it has been mounted to the folding frame. Fig. 12 illustrates a second embodiment of the position of the hook and loop attachments used to enclose the frame according to the present invention. In Fig. 12, Frame 120 uses hook 24 and loop 122 to enclose a frame comprising sides 126, 128, 130, and 132. Joints 134 again are mitered with a covering over the frame 120 holding the sides 126, 128, 130 and 132 together in the rectangular shape. Hooks 124 are placed along one face of side 126 and along one edge of side 132. Loop 122 has the same width of both hooks 124, and is as long as the length of either of hooks 124. The placement of loop 122 on hooks 124 allows the corner at where sides 126 and 132 meet to be held firmly in place while also having a strong resistance to any shearing or torquing force that may be applied at that joining location. With loop 122 readily accessible to the user, it may be removed to allow the disassembly of frame 120. It is also contemplated that one hook 124 may be on the outside face of side 132 and another also on the outside face of 126, such that loop 122 attaches to the hook 124 on side 126 and wraps around the edge formed by the joining of the side 126 with side 132 to meet with hook 124 on the outside face of side 132. This embodiment also allows for disassembly and has a high resistance to shearing and torquing forces. Furthermore, the edge of side 126 may receive glue to attach to the face of side 132 with hook 124 and loop 122 acting as a clamping means to allow the glue to cure for a permanent joint at where sides 126 and 132 adjoin. Glue also may be added between mitered joints 134. Thus the invention has been described with respect to certain embodiments thereof. It is also understood that variations and modifications can be made in the embodiment without departing from the essence or the scope or spirit of the invention. For example, rather than have angled joints, the joints may be formed so as to provide a round surface, or circular frame. In addition, the mitered joints may be reinforced with tape to prevent the paper or vinyl from tearing after repeated folding to allow the frame to be disassembled in desired applications. Such applications may include, for example, a foldable bookshelf for transporting from one location to another, a foldable desk for transporting from one room to another, or for the disassembly of a chest of drawers, thus allowing it to be moved from one location to another. It is also intended that the scope of the invention be limited only by the claims.

Claims

What is claimed is:

1. A foldable frame comprising a board having a first end, a second end and a permanently attached covering, the board having mitered joints cut at selected positions, which cuts pass through the board but not through the covering, and further comprising a hook attachment mechanism mounted to the first end and a loop attachment mechanism mounted to the second end such that as the frame folds about the mitered joints, the ends are attached together by the hook and loop attachment mechanisms.

2. The foldable frame of claim 1 further comprising alignment guides mounted on the first end of the board and alignment receptors mounted on the second end of the board for receiving said alignment guides.

3. The foldable frame of claim 1 wherein three mitered joints are positioned such that said frame defines a rectangle when said hook and loop attachment mechanisms attach to each other.

4. The foldable frame of claim 2 wherein said alignment guides are dowels and said alignment receptors are apertures having substantially the same diameter as said dowels.

5. The foldable frame of claim 1 further comprising permanent bonding means between said mitered joints.

6. The foldable frame of claim 1 wherein said hook attachment mechanism and said loop attachment mechanism are Velcro.

7. The foldable frame of claim 3 further comprising a bottom support mounted between the interior surfaces of said sides and a handle mounted on the exterior surface of one of said sides to define a drawer with a handle.

8. A foldable frame comprising a board having a first end, a second end and a permanently attached covering, the board having mitered joints cut at selected positions, which cuts pass through the board but not through the covering, and further comprising a hook attachment mechanism and a loop attachment mechanism mounted at the first end and the second end such that as the frame folds about the mitered joints, the ends are attached together by the hook and loop attachment mechanisms.

9. The foldable frame of claim 8 wherein said hook attachment mechanism further comprises a first hook portion and a second hook portion, wherein said first hook portion is mounted to said first end and said second end portion is mounted to said second end and wherein said loop attachment mechanism attaches to both said first hook portion and said second hook portion.

10. The foldable frame of claim 8 further comprising three mitered joints and four sides defining a first side, a second side, a bottom side and a top side, and further comprising a shelf mounted between said first side and said second side.

11. The foldable frame of claim 10 wherein said shelf attaches to first side and said second side with said hook attachment mechanism and said loop attachment mechanism, whereby a first end of said shelf and a second end of said shelf include said hook attachment mechanism and interior surfaces of said first side and said second side and include loop attachment mechanisms.

12. The foldable frame of claim 8 wherein said hook attachment mechanism and said loop attachment mechanism are comprised of Velcro.

13. The foldable frame of claim 12 wherein said Velcro is attached to said foldable frame with urethane glue.

14. The foldable frame of claim 9 wherein said covering comprises paper.

15. The foldable frame of claim 9 wherein said covering comprises vinyl.

16. A foldable drawer comprising a board having a first end, a second end and a permanently attached covering, the board having mitered joints cut at selected positions, which cut pass through the board but not through the covering, thereby defining four side elements, and further comprising a hook attachment mechanism mounted to the first end and a loop attachment mechanism mounted to the second end, such that as the frame folds about the mitered joints, the ends are attached together by the hook and loop attachment mechanism, and a bottom shelf is mounted to the four side elements such that the four side elements and the top of the bottom shelf define the interior of a drawer, and a handle mounted to one of said side elements.

17. The foldable drawer of claim 16 wherein said bottom shelf attaches to said side elements with said hook attachment mechanism and said loop attachment mechanism.

18. The foldable drawer of claim 16 further comprising a pair of runners, one of which is attached to one side element and the other of which is attached to an opposing side element with said handle being attached to a third side element.

19. A foldable cabinet having a frame defined by a board having a first end, a second end and a permanently attached covering, the board having mitered joints cut at selected positions which cuts pass through the board but not through the covering, and further comprising a hook attachment mechanism mounted to the first end and a loop attachment mechanism mounted to the second end, such that as the board folds about the mitered joints, the ends are attached together by the hook and loop attachment mechanism, thereby defining a frame, said frame further comprising a pair of doors, one attached to a first side of said frame and a second attached to a second side of said frame and a back enclosure mounted to said frame.

20. The foldable cabinet of claim 19 further comprising a shelf mounted between said first side of said frame and said second side of said frame and a drawer slidably mounted between said first side and second side of said frame and below said shelf.

21. The cabinet according to claim 19 wherein said hook attachment mechanism and said loop attachment mechanism are Velcro.

22. The cabinet of claim 19 wherein said Velcro is attached using urethane glue.

23. The cabinet of claim 19 wherein said back cover is attached to said frame with said hook attachment mechanism and said loop attachment mechanism.

24. A foldable frame comprising: a first board having a first end and a miter cut second end; a second board having a miter cut first end and a miter cut second end; a third board having a first end and a miter cut second end; flexible attaching means for attaching the miter cut second end of the first board to a miter cut end of the second board and for attaching the miter cut second end of the third board to the other miter cut end of the second board; and, a hook mechanism attached to the first end of the first board and a loop mechanism attached to the first end of the third board whereby as the frame folds about joints, formed by the flexible attaching means at the miter cuts, the first ends of the first and third boards are fastened together by the engagement of the hook and loop mechanism.

25. The foldable frame of claim 24 further comprising at least one fourth board having a miter cut first and second end attached between the second board and the third board with the flexible attachment means.

26. The foldable frame of claim 24 wherein the hook and loop mechanisms are Velcro.

27. The foldable frame of claim 26 wherein the Velcro is attached to the boards with urethane glue.

28. The foldable frame of claim 24 wherein the attachment means is comprised of paper having an adhesive.

29. The foldable frame of claim 24 wherein the flexible attachment means is comprised of vinyl.