Patent Publication Number: US-8967743-B2

Title: Furniture component with floating top

Description:
This application claims the benefit of U.S. Provisional Application No. 61/353,533, filed Jun. 10, 2010, the entire disclosure of which is hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a furniture component, and in particular, to a furniture component having a floating top, together with methods for the use and assembly thereof. 
     BACKGROUND 
     Furniture components, such as desks and cabinets, are typically configured with a top. Often, it is desirable to provide a furniture component with a top that lies flush with the outer faces of the furniture component. This may present various manufacturing and assembly problems, however, because tolerance build-ups, dimensional stability, etc., may present various fit and finish problems, especially at the corners of the furniture component. 
     In some instances, the top may be elevated above a base structure to provide a “floating” appearance. Typically, however, the base structure is still configured with a top positioned below the floating top, with the top of the base structure presenting the same problems just discussed. In other instances, the floating top extends past the sides of the base, which may aid in obscuring the fit problems, but does not provide a clean profile for the furniture component and presents an extended edge that may be snagged or otherwise impacted. Such an extended top may also further limit the fit and aesthetics of the component when disposed against other components or walls. 
     SUMMARY 
     The present invention is defined by the following claims, and nothing in this section should be considered to be a limitation on those claims. 
     In one aspect, one embodiment of a furniture component includes a base having a back wall with a first outer vertical face, a first inner vertical face and a first upper edge. Each of a pair of horizontally spaced apart side walls have a second outer vertical face, a second inner vertical face and a second upper edge. A front wall includes a third outer vertical face and an third upper edge. At least the first and second upper edges are substantially coplanar. An inner support is connected to at least one of the back wall and/or the side walls. An outer top is supported by the inner support and includes a bottom surface spaced above the first and second upper edges and defines a visible gap therebetween. In one embodiment, the outer top and inner support are integrally formed. The outer top has a rear edge, a pair of horizontally spaced apart side edges and a front edge. The rear edge and the first outer vertical face are substantially coplanar, while the side edges and corresponding ones of the second outer vertical faces are also substantially coplanar. 
     In another aspect, one embodiment of the furniture component is configured with the third upper edge being substantially coplanar with the first and second upper edges. In addition, the third outer vertical face may be substantially coplanar with the front edge. 
     In yet another aspect, a method of assembling a furniture component includes connecting a back wall to a pair of horizontally spaced side walls, wherein the back wall includes a first outer vertical face, a first inner vertical face and a first upper edge, wherein each of the side walls includes a second outer vertical face, a second inner vertical face and a second upper edge, and wherein the first and second upper edges are substantially coplanar. The method further includes connecting an inner top to the back wall and the side walls such that an upper surface of the inner top is vertically spaced above the first and second upper edges. The method further includes supporting an outer top on the inner top wherein a bottom surface of the outer top is spaced above the first and second upper edges and defines a visible gap therebetween. A rear edge of the outer top is substantially coplanar with the first outer vertical face and a pair of horizontally spaced apart side edges of the outer top are substantially coplanar with the second outer vertical faces. 
     The various embodiments of the furniture component, and methods for the assembly and use thereof, provide significant advantages over other workstations. For example and without limitation, the furniture component has a clean, furniture component visual, with the various components lying substantially flush. At the same time, the gap conceals the various fit-up issues, for example at the corners. This in turn eases and facilitates the assembly process. 
     The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The various preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a front/top perspective view of one embodiment of a furniture component configured with a pair of drawers. 
         FIG. 1B  is a front/top perspective view of one embodiment of a furniture component having a door. 
         FIG. 1C  is a front/top perspective view of one embodiment of a furniture component having a peripheral frame. 
         FIG. 1D  is a front/top perspective view of one embodiment of a furniture component configured as a desk. 
         FIG. 2  is a side view of the furniture component shown in  FIG. 1A . 
         FIG. 3  is a rear/bottom perspective view of the furniture component shown in  FIG. 1A . 
         FIG. 4  is an exploded perspective view of the furniture component shown in  FIG. 1A . 
         FIG. 5  is an enlarged side view of the front corner of the furniture component shown in  FIG. 1A . 
         FIG. 6  is an enlarged interior side view of the rear corner of the furniture component shown in  FIG. 1A . 
     
    
    
     DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS 
     It should be understood that the term “plurality,” as used herein, means two or more. The term “longitudinal,” as used herein means of or relating to length or the lengthwise direction, for example from one side of a top to the other side thereof. The term “lateral,” as used herein, means situated on, directed toward or running from side to side. The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent. The terms “first,” “second,” and so on, as used herein are not meant to be assigned to a particular component so designated, but rather are simply referring to such components in the numerical order as addressed, meaning that a component designated as “first” may later be a “second” such component, depending on the order in which it is referred. It should also be understood that designation of “first” and “second” does not necessarily mean that the two components or values so designated are different, meaning for example a first edge may be the same as a second edge, with each simply being applicable to different components. 
     Referring to  FIGS. 1A ,  3  and  4 , a furniture component  2  is shown as including a back wall  28 , a pair of horizontally spaced side walls  4  and a front wall  22 ,  6 , which form a base. The back wall has upper and lower edges  30 ,  32 , inner and outer vertical faces  34 ,  36  and opposite side edges  38 . Likewise, the side walls  4  each have upper and lower edges  40 ,  42 , inner and outer vertical faces  48 ,  44  and opposite side edges  46 . The front wall may include various panels. For example, as shown in FIGS.  1 A and  2 - 6 , the front wall is formed by a pair of drawer fronts  22  and a toe kick panel  6 . Each of the front wall panels has upper and lower edges  50 ,  52 , opposite side edges  54  and inner and outer vertical faces  56 ,  58 . In other embodiments, the front wall may include one or more door panels  24  ( FIG. 1B ), or a peripheral frame  26  ( FIG. 1C ). The frame may define openings  60 , for example for shelves, or for receiving drawer or door panels. In one embodiment, the drawers are each configured with a pull  12 , and may include a lock mechanism  62 . It should be understood that the furniture component is not limited to the various cabinet embodiments shown, but may be configured as other furniture components, including for example and without limitation as a desk ( FIG. 1D ) having a knee space  64  formed in the front of the base beneath a top  10 . 
     Referring to  FIGS. 1A ,  3  and  4 , the inner faces  48 ,  34 ,  56  of the side walls, back wall and toe kick panel are connected with corner brackets  66  as beast shown in  FIG. 3 . A plurality of feet  68 , which may be vertically adjustable, are secured to each bracket  66 . The feet may be configured as glides, casters or other known devices. A bottom wall  70  is also connected to the inner faces of the side walls, back wall and toe kick panel. The side and back walls may be further connected with various brackets and fasteners. 
     As shown in  FIG. 4 , a pair of drawers  72 , configured as boxes, are slidably mounted on drawer guides  74  fastened to the inner vertical face  48  of the side walls. The drawer fronts  22 , or front wall, are then fastened to the front panel of the drawer box  72  with various fasteners. It should be understood that the drawer front may be configured as the front panel of the drawer box. 
     As shown in  FIGS. 1A-C  and  2 - 6 , the upper edges  30 ,  40  of the back and side walls are coplanar. In one embodiment, the upper edge  74  of the uppermost front wall is also coplanar with the upper edges  30 ,  40  of the back and side walls. In one embodiment, the back, side and front walls may have the same thickness, or substantially the same thickness. 
     Referring to FIGS.  2  and  4 - 6 , an inner support  80  is connected to the inner faces  34 ,  48  of the side and back walls with various fasteners. In one embodiment, the inner support is configured as a panel, or inner top. The various side, back, bottom and front walls may be made of various suitable materials, including without limitation a medium density fiberboard (MDF) with a high pressure laminate (HPL) and veneer. Other materials may include solid and wood laminates, plastic, metal and other suitable materials. In other embodiments, the inner support may be configured as one or more brackets (e.g., metal or wood) secured to the side and/or back walls. In these various embodiments, the inner support, including the inner top shown, has an upper surface  88  that is spaced above the upper edges  30 ,  40 ,  74  of the back, side and front walls. In one embodiment, the upper surface  88  is spaced less than or equal to about ⅛ inch above the upper edges  30 ,  40 ,  74 . In other embodiments, the upper surface  88  spaced is spaced less than or equal to about ¼ inch, or less than or equal to about ½ inch. In some embodiments, the minimum gap is about 0.06 inches. A lower surface  90  of the inner top is spaced below the upper edges  30 ,  40 ,  74  of the back, side and front walls. A pair of brackets  92 , configured in one embodiment as L-shaped brackets, are connected to the lower surface  90  and the inner faces  48  of the side walls to further support the inner top  80 . 
     An outer top  10  has a lower surface  94  supported by and connected to the upper surface  88  of the inner support  80 . The lower surface  94  is spaced above the upper edges  30 ,  40 ,  74  of the back, side and front walls and forms a visible gap (G) therebetween. In one embodiment, the gap (G) is less than or equal to about ⅛ inch (0.125 inches). In other embodiments, the gap (G) is less than or equal to about ¼ inch (0.25 inches), or less than or equal to about ½ inch (0.50 inches). The outer top  10  has opposite side edges  84  that are coplanar, or substantially coplanar, with the outer vertical face  44  of the side walls, a rear edge  86  that is coplanar, or substantially coplanar, with the outer vertical face  36  of the rear wall, and a front edge  82  that is coplanar, or substantially coplanar, with the outer vertical face  58  of the front wall. For example, in one embodiment, the outer vertical faces are horizontally spaced a maximum of 0.060 inches from the edges of the outer top. In some embodiments, the outer top may extend outwardly on one or more sides, or the on the front or back, such that a corresponding edge thereof is spaced from the outer vertical face thereof. In one embodiment, the outer top has a thickness (t) less than the thickness (T) of each of the side walls, back wall, front wall and inner top. In one embodiment, the thickness (t) of the outer top is about ½ the thickness (T) of the wall components. In other embodiments, the thickness (t) is between about ⅛ and ⅞ the thickness (T) of the other wall components, and in one embodiment between about ¼ and ¾ the thickness (T) of the other wall components. Of course, in other embodiments, the outer top may have substantially the same thickness as, or even a greater thickness than, one or more of the side walls, back wall or front wall. The inner and outer tops may be made of the same materials as the front, side and rear walls. 
     One method of assembling the furniture component includes connecting the back and side walls  28 ,  4  with the front toe kick panel  6 . The bottom and inner tops  70 ,  80  may also be connected to the side and back walls, and/or a front wall, such as the toe kick panel. Other front walls may be connected, for example by mounting drawers  22  or a door  24  on the side wall(s), and/or be connecting a peripheral frame  26  to the side walls. In one embodiment, the walls are connected such that the upper edges  30 ,  40 ,  74  thereof are coplanar. The inner support, configured in one embodiment as the inner top  80 , is then connected to the side and rear walls, and may be connected to the front wall, with the upper surface  88  spaced above the upper edges  30 ,  40 ,  74  of the back, side and front walls. The outer top  10  is then secured to the inner support  80 , for example with fasteners, adhesive, etc. such that the lower surface  94  thereof is spaced above the upper edges of the rear, side and front walls, but with the edges  82 ,  84 ,  86  of the outer top  10  being coplanar with the outer faces  58 ,  44 ,  36  of the various wall components. In other embodiments, the inner support and outer top are integrally formed from the piece of material, for example by routing or otherwise machining a peripheral edge of the top to form the bottom surface of the outer top thereof and to define side edges of the inner support which may then be mated with one or more of the side or back walls. In this way, the gap (G) created between the bottom surface  94  of the outer top  10  and the various walls conceals any deficiencies in the shape, form and/or fit of the various walls and the outer top. 
     Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.