Floating Furniture Top Structure for Concealing Fit-Up Issues
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Solution Overview
Problem
Furniture components with floating tops face manufacturing and assembly challenges due to tolerance build-ups and dimensional stability issues, leading to fit and finish problems, especially at corners, and extended edges that can be snagged or impact aesthetics.
Innovation Solution
A furniture component design featuring a base with coplanar upper edges and an inner support system that allows an outer top to be spaced above these edges, creating a visible gap that conceals fit-up issues while maintaining a clean profile, with the outer top being either integrally formed or separately secured to the inner support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the top is positioned flush with the outer faces of the base structure, then a clean profile is achieved, but tolerance build-ups and dimensional stability issues cause fit and finish problems
Solution Approach 1:
The patent divides the top structure into two separate components: an outer top and an inner top. The inner top is positioned flush with the outer faces of the base structure to maintain the clean profile, while the outer top is elevated above the inner top to create a visible gap that conceals fit and finish problems. This segmentation allows each component to serve its specific function without compromising the other.
2Manufacturing precision
If the floating top extends past the sides of the base, then fit problems are obscured, but the extended edge can be snagged and limits aesthetics
Solution Approach 1:
The patent resolves this contradiction by elevating the outer top to a different vertical dimension above the inner top, creating a visible gap. This vertical separation allows the outer top to extend slightly beyond the base structure to conceal fit problems, while the elevated position prevents the extended edges from being at the same level as the base, thereby eliminating the snagging hazard.
3Shape
If the top is elevated above the base structure to provide a floating appearance, then aesthetics are improved, but the base structure still presents fit and finish problems
Solution Approach 1:
The patent introduces an inner top as an intermediary component between the base structure and the outer top. The inner top is positioned flush with the outer faces of the base structure, serving as a mediator that provides a clean, finished surface that conceals any fit and finish problems of the base structure, while still allowing the outer top to be elevated for the floating appearance.
4Manufacturing precision
If an extended top is used to obscure fit problems, then manufacturing tolerances are masked, but the component limits fit and aesthetics when disposed against other components or walls
Solution Approach 1:
The patent segments the top into an inner top that is flush with the base structure and an outer top that is elevated. The inner top provides the clean profile that enables proper fit and aesthetics when the furniture component is disposed against other components or walls, while the elevated outer top masks the tolerance issues through the visible gap it creates.
Data Source
AI summary
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. A pair of horizontally spaced apart side walls each have a second outer vertical face, a second inner vertical face and a second upper edge. The first and second upper edges are substantially coplanar. An outer top includes a bottom surface spaced above the first and second upper edges and defines a visible gap therebetween. The outer top has a rear edge and a pair of horizontally spaced apart side edges. The rear edge and the first outer vertical face are substantially coplanar, and the side edges and second outer vertical faces are substantially coplanar. A method of assembling and using the furniture component are also provided.