US20260144363A1
2026-05-28
19/397,722
2025-11-21
Smart Summary: A new system uses rails and end caps to create modular furniture that can be easily assembled and customized. Each rail connects to an end cap, which helps join multiple rails together at a joint. The end caps have special gear elements that make the connections strong and secure. They also feature protruding parts to keep the end caps firmly in place. This design allows for the addition of shelves and other components, making the furniture versatile and adaptable. 🚀 TL;DR
A rail-and-node frame system for modular furniture includes a plurality of rails each of which including an end cap designed to couple to the rails and to join together several converging rails at a knuckle joint. The end cap may include gear elements operable to facilitate secure coupling to the rails, and may further include one or more protruding elements to secure the end cap within the knuckle joint. The rails are designed to receive and support one or more shelving units or other components of the modular furniture.
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A47B47/0016 » CPC main
Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements Node corner connectors, e.g. cubic
A47B47/0091 » CPC further
Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements Modular arrangements of similar assemblies of elements
A47B91/024 » CPC further
Feet for furniture in general; Adjustable feet using screw means Foot attached to a rotating bolt supported in an internal thread
A47B47/00 IPC
Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements
A47B91/02 IPC
Feet for furniture in general Adjustable feet
This application is a nonprovisional of and claims the benefit under 35 U.S.C. § 119(e) from U.S. Provisional Ser. No. 63/723,861 , filed Nov. 22, 2024, the disclosure of which is incorporated by reference herein in its entirety.
The present disclosure relates generally to the field of frame construction, and particularly, to framing systems for furniture designed to streamline manufacture and assembly processes and improve overall functionality.
Modular furniture, including frames constructed of rods joined by nodes, are well known. One such modular furniture system includes tubular rods that are connected to ball-shaped nodes by threaded bolts, as described in Swiss Patent No. CH 429 317, granted Jan. 31, 1967. Friction wedges fitted into the ends of the tubular rods are drawn together when the bolt is threaded into the ball node and tightened, causing the friction wedges to move radially outward into firm contact with the inner surface of the rod, while drawing the end of the rod into firm contact with the outer surface of the ball node. Many variations on this ball-node design have been developed over time. Most of these prior furniture designs rely on threaded fasteners that extend longitudinally and coaxially from ends of tubular rods and are threaded into or through the nodes.
Some known ball-node type modular furniture frame systems include conductive pathways for distributing electricity to integrated lighting and/or other electrical components, as described, for example, in U.S. Pat. No. 10,302,112, issued May 28, 2019.
Node and strut constructions have also long been utilized in trusses and space-frames for load-bearing applications such as bridges and roof supports.
Some modular structural framing systems utilize struts or beams that are not tubular rods but are designed as open beams having webs and/or fins with flat surfaces and rectilinear cross-sectional shapes. Examples of such modular structural framing systems are described in U.S. Pat. Nos. 2,986,241 issued May 30, 1961, and 9,879,413 issued Jan. 18, 2018.
The present inventors have identified a need for improved framing systems for furniture and the like that are easy to assemble from a relatively small number of different modular components and which, when assembled, provide an aesthetically pleasing appearance with improved functionality. Additional aspects and advantages will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings.
The drawings depict only several examples in accordance with the disclosure and are therefore not to be considered limiting in scope. Example embodiments will be described with additional specificity and detail through use of the accompanying drawings, in which:
FIG. 1 illustrates an assembled item of furniture in the form of a shelving unit in accordance with one example embodiment.
FIG. 2 is a front view of the shelving unit of FIG. 1.
FIG. 3 is a side view of the shelving unit of FIG. 1.
FIG. 4 is a top view of the shelving unit of FIG. 1.
FIG. 5 is an enlarged partially exploded detail view of a portion of a frame system of the shelving unit of FIG. 1, with shelves omitted.
FIG. 6 is an enlarged pictorial view of a joint of the frame system of FIG. 5.
FIG. 7 is a pictorial view of an end cap or clip component of the frame system of FIG. 5.
FIG. 8 illustrates a tenon assembly comprising a pair of the end caps or clips of FIG. 7 in a mated configuration.
FIG. 9 is a pictorial view of the frame system of FIG. 5 shown in an assembled configuration with a shelf partially exploded to illustrate insertion of the shelf into the frame during assembly of the shelving unit in accordance with an example embodiment.
FIG. 10 illustrates various items included in a kit of components for assembly into the shelving unit of FIG. 1, or other suitable furniture, in accordance with an example embodiment.
FIG. 11 is a perspective view of a foot component of the shelving unit and frame system of FIG. 1 in accordance with one example embodiment.
FIG. 12 is a front elevation of the foot component of FIG. 11.
FIG. 13 is a top view of the foot component of FIG. 11.
FIG. 14 is an enlarged partially exploded detail view of a portion of a frame system for a shelving unit in accordance with another example embodiment.
FIG. 15 is an exploded view illustrating details of a male geared end cap of the frame system of FIG. 14.
FIG. 16 is an enlarged exploded view illustrating details of the male geared end cap of FIG. 15.
FIG. 17 is a bottom perspective view of the male geared end cap of FIG. 15.
FIG. 18 is a cross-sectional view of a five-way knuckle of the frame system of FIG. 14.
FIG. 19 is a bottom perspective view of a female geared end cap of a frame system for a shelving unit in accordance with another example embodiment.
FIG. 20 is an exploded view illustrating details of the female geared end cap of FIG. 19 in accordance with another example embodiment.
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth to provide a sufficient understanding of the subject matter presented herein. But it will be apparent to one of ordinary skill in the art that the subject matter may be practiced without some of these specific details.
This disclosure generally relates to frame systems for use in furniture, cabinetry, and the like, and to furniture, cabinetry and other items including such frame systems. In addition, the disclosure relates to methods of manufacture and assembly of framing systems, furniture, cabinetry and the like. The subject matter disclosed herein is described in the context of an example embodiment comprising a modular shelving unit that can be readily assembled by the customer. However, various other types of furniture—such as racks or shelves for clothing or other items in residential or retail spaces, desks, file cabinets, chests of drawers, etc. —may utilize the frame systems disclosed herein, or variations thereon. Moreover, various other types of structures may be assembled from rail and node components consistent with the present disclosure. Framing components and systems consistent with the present disclosure may also be utilized in cabinetry and other furnishings, carts and other vehicles, in structures for buildings or construction, and in virtually any other item requiring a structural frame or supportive truss-like structure.
FIG. 1 illustrates an item of furniture 100 in the form of a shelving unit, assembled utilizing a rail-and-node framing system 102 in accordance with an embodiment of the present disclosure. The shelving unit 100 of FIG. 1 is illustrated with equally sized and spaced shelves 104 in accordance with one example configuration. In other embodiments, the framing system 102 may be made up of different sized rails 204 (FIG. 2) so as to allow for a very wide variety of shelf sizes, spacings, and arrangements, including non-cubic and non-rectangular arrangements as will be made apparent by the following description of various components of the framing system 102.
FIGS. 2, 3, and 4 collectively are respective front, side, and top views of the furniture 100 of FIG. 1. With general reference to FIGS. 2-4, framing system 102 of furniture 100 includes a set of horizontally and vertically arranged rails 204 which are joined at several connection points by nodes 202 to together form a spatial frame structure that supports shelves 104 (see FIG. 1). With reference to FIG. 2, rails 204 may be characterized as beams or, in some applications, as struts. Nodes 202 form joints that join together two or more rails 204 as illustrated. Nodes 202 may be characterized as joints, corners, brackets, corner keys, or knuckles, for example. In the embodiment of the shelving unit illustrated in the figures, the nodes 202 are joints or knuckles that join together three, four, or five rails 204, depending on a particular location of the node 202 in the furniture 100. The number of rails 204 joined by the node 202 will typically dictate the design of the node 202 as is further described below with particular reference to FIG. 10.
FIG. 5 provides a detailed view of the framing system 102 of furniture 100 as collectively illustrated in FIGS. 1-4. FIG. 5 illustrates two nodes 202 each in the form of a five-way knuckle 502 that joins together five converging rails 204. With reference to FIG. 5, each five-way knuckle 502 includes five cylindrical legs 504 extending in orthogonal directions from the center of the node 202. Five-way knuckle 502 is hollow and may have controlled wall thicknesses which may be essentially the same throughout the node 202 and may be formed of metal or high-strength plastic for example. In a preferred embodiment, five-way knuckle 502 and other nodes 202 disclosed herein are made of metal, such as steel or aluminum, and may be machined, cast, or formed by powder metallurgy, such as a powdered metal sintering, forging, hot isostatic pressing, or metal injection molding process, for example.
Each rail 204 is typically joined at each end thereof to a node 202, such that the rails 204 form beams or struts of the framing system 102. In the embodiment illustrated, rails 204 have a cross-shaped or plus-shaped profile made up of four fins 514 that radiate from a central hub and axis of the rail 204 at 90-degree angles relative to adjacent fins 514, to thereby form the cross-shaped or plus-shaped cross-sectional profile. This unique cross-shaped profile provides built-in support for shelves 104 and may also provide space for a hidden LED lighting strip and/or cables (not illustrated) along the inner underside of the rails 204, in addition to providing structural support and strength. In other embodiments, rail 204 may have a different cross-sectional profile, such as star-shaped or the shape of a common structural beam, such as an I-beam or H-beam, for example. Rails 204 are preferably made of extruded aluminum or another extruded metal, such as stainless steel, allowing them to be economically fabricated in various different lengths for different furniture and/or structural configurations.
In an example assembly process, a pair of clips 506 (or end caps, inserts, plugs, or keys) are mated together around each of the end portions 508 of each rail 204. In one example embodiment, each clip 506 includes a pair of bosses including a first peg 708 or other suitable locking element (see FIG. 7) that extends through an opening or hole 510 formed in and extending through the end portion 508 of the rail 204 and into a corresponding first hole or seat 710 (FIG. 7) formed in the mating clip 506 so as to form a tenon assembly 512 (see also FIG. 8) at the end of the rail 204. The tenon assembly 512 is slidably fitted into a bore 516 (mortise) formed in the leg 504 of node 202, while the end portion 508 of the rail 204 is partially fitted into the bore 516. In an assembled configuration, each of the fins 514 of the rail 204 is slidably seated into a corresponding one of multiple slots 518 formed in the cylindrical walls 524 of each of the legs 504. This configuration resists or prevents twisting of the rails 204 relative to the nodes 202. In the embodiment illustrated, the legs 504 are illustrated as cylindrical shapes. In other embodiments (not illustrated), the legs 504 of some or all of the nodes 202 may be made in a shape other than cylindrical, such as boxes, hollow triangular tubular sections, hollow hexagons, or hollow octagons, for example, in which case clips 506 would be shaped in a corresponding cubic or trapezoidal shape so that the tenon assembly 512 closely slidably fits into the leg in a similar fashion as described herein.
A set screw 520 (also sometimes referred to as a grub screw) penetrates a wall 524 of leg 504 and is threaded into a threaded hole 522 in the wall 524 and tightened against or into one of the clips 506 to retain the rail 204 to the node 202. The set screw 520 may preferably pass through one of the pair of clips 506 that is proximal of the threaded hole 522 (and optionally through a threaded hole in the proximal clip, not illustrated), with the distal end of the set screw 520 pressing against an inner surface of the other (distal) clip 506, causing the pair of clips 506 to flare outwardly, in turn causing the tenon assembly 512 to expand and bind in place against the inner surface of the wall 524 of leg 504. In other embodiments (not illustrated), set screw 520 may be made longer and threaded into threaded hole 522 and through a hole extending through both clips 506, and optionally through rail 204. In still other embodiments, a pin may be used in place of set screw 520 and press-fitted into hole 522 and through the pair of clips 506 and rail 204 to lock together the tenon assembly 512, node 202, and rail 204.
FIG. 6 provides a close-up view of a joint 600 formed by the five-way knuckle 502. FIG. 6 illustrates set screws 520 threaded into each of the legs 504 of node 202 to lock each of the rails 204 to a leg 504 of the five-way knuckle 502. Each of the set screws 520 is illustrated with a hex socket that receives a hex key tool for tightening the set screw 520 in accordance with an example embodiment. Each of the nodes 202, rails 204, clips 506, legs 504, and slots 518 (FIG. 5), is preferably sized so that the various parts fit together neatly or snugly, with smooth and flush mating surfaces. For example, clips 506 are sized with a length such that ends of the clips 506 are flush with an end surface of the corresponding leg 504 into which the clips are inserted; and the fins 514 of rails 204 are sized to be approximately flush with an outer cylindrical surface of the leg 504 when assembled.
The shape of the nodes 202 provides a simple geometric form and hidden attachment method for a minimalistic aesthetic that may be appealing to the high-end furniture market. The means by which the node is attached to the rail is unique. It secures the rail in position with a simple mechanical fastener, allowing the furniture 100 (or another suitable item) to be readily assembled and disassembled by the user. The arrangement of clips 506 and set screws 520 also maintains a clean visual appearance for the joint 600, capping the end of each leg 504 of the node, giving it the impression of a solid form. In addition, the modular construction of common components provides a consistent visual appearance for various types of furniture that can be made using the framing systems disclosed herein.
FIG. 7 illustrates additional details of clip 506 in accordance with an example embodiment. With reference to FIG. 7, clip 506 includes a main body 702 and a pair of tines 704 extending longitudinally from the main body 702 and spaced apart from one another to form a slot 706 therebetween that is sized to receive a fin 514 of rail 204. A pair of bosses and holes are formed on an inner face of clip 506, including a first peg or locking element 708 (first boss) extending from an inner face of one of the tines 704 and a second peg or locking element 712 (second boss) extending from main body 702. At a mirrored location on clip 506 are formed respective first hole or seat 710 and second hole or seat 714 (which may be blind holes as illustrated or through holes) so that when a pair of first and second clips 506 are assembled together as described previously, the first peg 708 of a first clip 506 is received in the first hole 710 of the mating second clip 506, and the second peg 712 of the first clip 506 is received in the second hole 714 of the mating second clip 506. Thus, the bosses (pegs 708, 712) and holes 710, 714 of mating clips 506 cooperate with one another so that the clips 506, when mated, form a tenon assembly 512 as illustrated in FIG. 8.
FIG. 9 illustrates a final step in accordance with an example method of assembling a shelving unit of furniture 100, wherein shelves 104 are seated onto a frame formed of rails 204 of the framing system 102. In particular, the inwardly extending horizontal fin 514 of each of the rails 204 bordering each shelf 104 provides a support surface against which the shelf 104 is seated. The height of the vertical fins 514 of the rails 204 may be sufficient to obscure the edge of the shelf 104, thereby hiding cut edges of the shelving material, and may be approximately flush with the top surface of the shelf 104 to provide a clean aesthetic appearance. In an example embodiment, shelves 104 may include notches 902 at their corners to accommodate the legs 504 of nodes 202 and to fit neatly together therewith.
FIG. 10 illustrates elements of a kit 1000 that may be assembled to make furniture 100. The modular design of framing system 102, which can be easily assembled by the user or customer, allows for the kit 1000 to be shipped in a relatively flat package, reducing transportation and storage costs. The kit 1000 may include various nodes 202 including one or more five-way knuckles 502, four-way knuckles 1002, and/or three-way knuckles 1004, together with clips 506 and rails 204, and optionally shelves 104 or other panel or drawer components, and feet 206.
FIGS. 11-13 collectively provide detailed views of a leveling foot 1102 which may be utilized for feet 206 in accordance with an example embodiment. With general reference to FIGS. 11-13, leveling foot 1102 includes a plug body 1104 with a threaded hole through which a threaded rod 1106 is threadably inserted. A shoe 1108 is coupled or otherwise attached to a bottom of the threaded rod 1106. The length of the portion of threaded rod 1106 extending downwardly from the plug body 1104 is adjusted for leveling the furniture 100 by rotating the shoe 1108 or threaded rod 1106 relative to the plug body 1104.
FIGS. 14-20 collectively provide details of other example embodiments for a rail-and-node framing system 1202 that may be used in assembling furniture (e.g., furniture 100) in a similar fashion as described previously with reference to frame system 102 of FIGS. 1-13. It should be understood that the framing system 1202 may include the same or substantially similar features as the framing system 102 of FIGS. 1-13. Accordingly, some features of framing system 1202 may be described briefly or otherwise omitted in the following description to avoid obscuring more pertinent features of the embodiment with the understanding that features described with reference to framing system 102 (and furniture 100) and other components in FIGS. 1-13 may also apply to framing system 1202 (and its use to assemble furniture similar to furniture 100).
With reference to FIG. 14, framing system 1202 includes a plurality of rails 1204 designed to be joined at a node 1206 in a substantially similar fashion as described previously with reference to FIGS. 1-13. As illustrated in FIG. 14, rails 1204 may include substantially the same profile and overall features as described previously with reference to rails 204 as illustrated in FIG. 5. FIG. 14 illustrates node 1206 in the form of a five-way knuckle 1208 designed for joining together five converging rails 1204 at node 1206. As noted previously, rails 1204 may be characterized as beams or, in some applications, as struts, designed to support shelves (e.g., shelves 104) or other components of the assembled furniture (e.g., furniture 100). The framing system 1202 further includes a male geared end cap 1210 designed to couple with end portions 1212 of each rail 1204. End cap 1210 facilitates coupling of the rails 1204 with five-way knuckle 1208 at node 1206 in a similar manner as previously described with reference to framing system 102. Additional details of male geared end cap 1210 and its functionality in the frame system 1202 are provided in further detail below with reference to FIGS. 15-18.
FIGS. 15-16 are each exploded views illustrating additional details of the male geared end cap 1210 of the frame system 1202. With collective reference to FIGS. 15-16, male geared end cap 1210 includes a main body 1214 and four tines 1216 extending longitudinally from main body 1214 and spaced apart from one another to define an opening 1218 therebetween, the opening 1218 sized to receive fins 1220 of rails 1204. In one embodiment, opening 1218 may include a matching cross-shaped profile corresponding to the profile created by fins 1220 of rails 1204. In other embodiments, opening 1218 may have another suitable profile depending on the corresponding profile of fins 1220 for a particular rail 1204.
With reference to FIG. 16, end cap 1210 includes a first gear 1222 and a second gear 1230 that cooperate with one another to accommodate tightening of end cap 1210 onto rails 1204 during the assembly process as further described below. With reference to FIG. 16, first gear 1222 includes a plurality of spaced-apart teeth 1224 formed around a first portion 1226 thereof, and a threaded shaft 1228 extending downwardly from the first portion 1226. Second gear 1230 also includes a plurality of spaced-apart teeth 1232 formed on a first portion 1234 thereof, and a shaft 1236 extending downwardly from first portion 1234. The shaft 1236 includes a notched end face 1238 designed for engaging a screwdriver or other suitable drive element to facilitate operation of the gears 1222, 1230 as further described in detail below. In some examples, notched end face 1238 may be designed to receive and engage with a screwdriver with any suitable head style, such as a flathead, Phillips, hex, square, etc.
With reference to FIG. 15, main body 1214 of end cap 1210 includes a first cavity 1240 sized and dimensioned for receiving first gear 1222. Main body 1214 further includes an opening (not shown) substantially centered along a central axis extending between the four tines 1216 through which the threaded shaft 1228 of first gear 1222 extends outwardly of main body 1214 (see FIG. 17). Main body 1214 further includes a second cavity 1242 adjacent first cavity 1240, the second cavity 1242 formed within one of the tines 1216. Cavity 1242 includes an opening 1244 along an end face 1246 of the tine 1216 to facilitate access to notched end face 1238 of second gear 1230 (see also FIG. 17) for driving second gear 1230, which in turn drives first gear 1222 to tighten end cap 1210 onto rails 1204 as further described below.
With collective references to FIGS. 15-16, end cap 1210 includes a main cap 1248 designed to couple with main body 1214 to retain the gears 1222, 1230 in position therein. As illustrated, main cap 1248 includes a first bore 1250 and a second bore 1252 for receiving and accommodating upper portions of gears 1222, 1230 when each is seated in their respective cavities 1240, 1242 within main body 1214. Main cap 1248 further includes a pair of through holes 1254 extending therethrough for receiving fasteners 1256 to secure main cap 1248 to main body 1214. As illustrated in FIG. 15, main body 1214 includes corresponding openings 1258 extending at least partially therein for receiving fasteners 1256 to couple together main cap 1248 and main body 1214.
With collective reference to FIGS. 14-18, the following describes an example coupling of male geared end cap 1210 with rails 1204 in accordance with one embodiment. With reference to FIGS. 15-16, end portion 1212 of rails 1204 includes a threaded opening 1260 formed along a central axis extending between fins 1220 as illustrated. When the components are coupled during assembly of the frame system 1202, assembled male geared end cap 1210 is aligned such that threaded shaft 1228 of first gear 1222 extends into threaded opening 1260 of rail 1204. In this configuration, respective fins 1220 of rail 1204 are positioned such that they extend into corresponding portions or slots of opening 1218 formed between tines 1216 of end cap 1210. Once the components are aligned as described, a screwdriver or other drive element may be used in conjunction with notched end face 1238 to drive rotation of second gear 1230 within end cap 1210. Rotation of second gear 1230 in turn rotates first gear 1222 to advance threaded shaft 1228 into threaded opening 1260 of rail 1204 and securely couple male geared end cap 1210 with rail 1204. Additional details of an overall assembly process for the frame system 1202 are further described below.
With collective reference to FIGS. 14-18, five-way knuckle 1208 includes five cylindrical legs 1262 extending in orthogonal directions from the center of node 1206. Five-way knuckle 1208 is hollow and may have controlled wall thicknesses which may be essentially the same throughout the node 1206 and may be formed of metal or high-strength plastic for example. To assemble frame system 1202, male geared end cap 1210 is advanced toward a central bore 1264 formed in the leg 1262 such that end cap 1210 is slidably fitted into central bore 1264. End cap 1210 is then rotated within the central bore 1264 so that each opening or slot 1218 of end cap 1210 aligns with a corresponding slot 1266 formed in the cylindrical walls 1268 of each leg 1262. With reference to FIG. 18, five-way knuckle 1208 includes one or more recessed channels 1270 formed within corresponding cylindrical walls 1268 of legs 1262. As illustrated in FIG. 18, each of the legs 1262 may include one or more recessed channels 1270 therein. As illustrated in FIG. 16, main body 1216 of geared end cap 1210 includes one or more protruding tabs 1272 extending outwardly from an exterior surface thereof. As end cap 1210 is rotated within central bore 1264, each tab 1272 is seated within and moves along a corresponding recessed channel 1270 to secure the geared end cap 1210 within five-way knuckle 1208.
Thereafter, with end cap 1210 in position within central bore 1264, fins 1220 of rail 1204 are advanced into a corresponding one of aligned slots 1218 (of end cap 1210), 1266 (of leg 1262). The insertion of the fins 1220 into the aligned slots 1218, 1266 retain tabs 1272 locked in channel 1270 to secure the components together. Once the fins 1220 have been advanced into the respective slots 1218, 1266, the gears 1222, 1230 may be driven as described above to tighten the coupled components together. In a similar fashion as described previously with reference to FIG. 9, once the components of the framing system 1202 have been assembled together as desired, shelves or other suitable components may be seated thereon to complete furniture assembly.
The coupled configuration described above resists or prevents twisting of the rails 1204 relative to the nodes 1206. In the embodiment of FIG. 14, the legs 1262 are illustrated as cylindrical shapes. In other embodiments (not illustrated), the legs 1262 of some or all of the nodes 1206 may be made in a shape other than cylindrical, such as boxes, hollow triangular tubular sections, hollow hexagons, or hollow octagons, for example, in which case, geared end caps 1210 would be shaped in a corresponding cubic or trapezoidal shape so that it closely slidably fits into the leg in a similar fashion as described herein.
FIGS. 19-20 collectively illustrate an example embodiment of a female geared end cap 1300. End cap 1300 may include the same or substantially similar features as the male geared end cap 1210 of FIGS. 14-18 except as otherwise described herein. Accordingly, some features of geared end cap 1300 may be described briefly or otherwise omitted in the following description to avoid obscuring more pertinent features of the embodiment with the understanding that features described with reference to geared end cap 1210 FIGS. 14-18 may also apply to geared end cap 1300 of FIGS. 19-20. Briefly, with reference to FIG. 20, female geared end cap 1300 includes a main cap 1348 coupled to a main body 1314, where the main body 1314 houses gears 1322, 1330 and includes tines 1316 for coupling with a rail 1304 in a similar fashion as described with reference to male geared end cap 1210.
With reference to FIGS. 19-20, first gear 1322 includes a threaded opening 1324 extending through an interior portion of the gear 1322, where threaded opening 1324 is designed to receive a threaded shaft 1360 of rail 1304 (the location of these components is essentially reversed as compared to the male geared end cap 1210 of FIGS. 14-18). In a similar fashion as described previously, female geared end cap 1300 may be coupled to rail 1304 via engagement of the threaded shaft 1360 into threaded opening 1324. The components may be coupled to one another using a screwdriver or other drive element against notched end face 1338 (see FIG. 19) to rotate second gear 1330, which in turn drives first gear 1322 in a similar fashion as described previously to secure the components together. End cap 1300 and rails 1304 may be coupled to one another via knuckles (not shown) in a similar fashion as described previously with reference to FIGS. 14-18.
Rail-and-node framing systems 102, 1202 according to the present disclosure provide a modular, extensible solution for the creation of furniture, cabinetry, and the like, having a minimalist aesthetic that provides a powerful visual identity that is in large part an outgrowth to the structural problems it solves. Framing solutions provided by the systems and methods disclosed herein are potentially limitless. Moreover, as previously mentioned, rail-and-node framing systems utilizing the principles of the embodiments disclosed herein may be employed as trusses, space frames (3D trusses) and other structural assemblies for playgrounds, vehicles, and buildings and load-bearing items.
Several embodiments of a rail-and-node framing system 102, 1202 are illustrated herein in the context of their use for assembling furniture 100. However, such framing systems 102, 1202 may be used to support other suitable assemblies as noted previously. Accordingly, it is to be appreciated that any one of the above embodiments, and/or components or specific features associated therewith, may be combined with one or more other embodiments and/or features in accordance with the disclosed systems and methods. Moreover, it is noted that the disclosure is intended to be merely illustrative of the present systems and methods and should not be construed as limiting the appended claims to any particular embodiment or group of embodiments.
It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the claims.
1. A frame system comprising:
a rail including one or more fins extending outwardly from a central portion thereof;
an end cap including a plurality of tines with an opening defined between adjacent tines, wherein the one or more fins of the rail extend into a corresponding opening between adjacent tines of the end cap to couple the rail and end cap together; and
a connection member including at least one leg, the leg including a plurality of slots formed thereon and a central bore extending at least partially therethrough, wherein the leg receives the end cap through the central bore and the one or more fins of the rail extend at least partially into a corresponding slot of the plurality of slots to secure the rail and end cap with the connection member.
2. The frame system of claim 1, the end cap further comprising:
a main body including a first cavity formed therein; and
a gear drive seated within the first cavity of the main body, the gear drive operable to couple the end cap and rail with one another.
3. The frame system of claim 2, wherein the gear drive includes a threaded shaft extending outwardly of the first cavity and the main body, and wherein the rail includes a threaded opening extending therethrough, and wherein the gear drive is operable to advance the threaded shaft into the threaded opening to couple the end cap and rail together.
4. The frame system of claim 2, wherein the gear drive includes a body with a threaded opening extending therein, and wherein the rail includes a threaded shaft extending outwardly therefrom, and wherein the gear drive is operable such that the threaded shaft advances into the threaded opening to couple the end cap and rail together.
5. The frame system of claim 2, wherein the main body further includes a second cavity, and wherein the gear drive includes a first gear with a threaded shaft disposed within the first cavity and a second gear disposed within the second cavity, the first gear and the second gear in operable communication with one another, and wherein the second gear drives the first gear to advance the threaded shaft into a corresponding threaded opening on the rail to couple the end cap and rail with one another.
6. The frame system of claim 5, wherein the second cavity includes an opening on a surface of the main body, and wherein the second gear includes a notched end face accessible via the opening on the surface of the main body, the notched end face configured to receive and engage a tool for manually driving the second gear.
7. The frame system of claim 6, wherein the second cavity is formed within a corresponding tine of the plurality of tines.
8. The frame system of claim 6, the end cap further comprising a main cap removably coupled to the main body, the main cap including a first recess for receiving at least a portion of the first gear and a second recess for receiving at least a portion of the second gear.
9. The frame system of claim 1, wherein the leg of the connection member further includes a receiving channel formed therein, and wherein the end cap further includes a protrusion formed along an exterior surface thereof, the protrusion seated within the receiving channel when the end cap is seated within the central bore of the connection member.
10. The frame system of claim 1, wherein the rail includes a first fin, a second fin, a third fin, and a fourth fin, and wherein the first fin is substantially orthogonal relative to the second fin, the second fin is substantially orthogonal relative to the third fin, the third fin is substantially orthogonal relative to the fourth fin, and the fourth fin is substantially orthogonal relative to the first fin to create a cross-shaped profile for the rail.
11. The frame system of claim 10, wherein the rail is configured to receive a support a substantially planar shelf on at least one of the first fin, second fin, third fin, and/or fourth fin.
12. The frame system of claim 1, further comprising:
a plurality of rails, each rail including one or more fins extending outwardly from a central portion thereof; and
a plurality of end caps, each end cap coupled to a corresponding rail of the plurality of rails, where each end cap further includes a plurality of tines with an opening defined between adjacent tines, wherein the one or more fins of the corresponding rail extend into a corresponding opening between adjacent tines of the corresponding end cap, thereby defining a plurality of combined end cap and rail assemblies,
wherein the connection member includes a plurality of legs, each leg including a plurality of slots formed thereon and a central bore extending at least partially therethrough, wherein each leg of the plurality of legs receives a corresponding combined end cap and rail assembly of the plurality of combined end cap and rail assemblies.
13. The frame system of claim 1, wherein the end cap includes a first member and a second member, each of the first member and the second member comprising:
a main body including a pair of tines extending longitudinally from the main body and spaced apart from one another to form a slot therebetween sized to receive a fin of the one or more fins of the rail;
a first boss extending from an inner face of one of the tines and a second boss extending from the main body and offset from the first boss; and
a first opening formed on an inner face of the other of the tines and a second opening formed on the main body.
14. The frame system of claim 13, wherein the first boss of the first member extends through a first rail opening on an end portion of the rail and into the first opening of the second member, and wherein the first boss of the second member extends through a second rail opening on an end portion of the rail and into the first opening of the first member when the end cap and rail are coupled with one another.
15. The frame system of claim 14, wherein the second boss of the first member extends into the second opening of the second member, and wherein the second boss of the second member extends into the second opening of the first member.
16. The frame system of claim 14, wherein a first fin of the rail extends into the slot of the main body of the first member, and wherein a second fin of the rail extends into the slot of the main body of the second member.
17. A frame system comprising:
a plurality of rails, each rail including one or more fins extending outwardly from a central portion thereof;
a plurality of end caps, each end cap coupled to a corresponding rail of the plurality of rails, where each end cap further includes a plurality of tines with an opening defined between adjacent tines, wherein the one or more fins of the corresponding rail extend into a corresponding opening between adjacent tines of the corresponding end cap; and
a connection member including a plurality of legs, each leg including a plurality of slots formed thereon and a central bore extending at least partially therethrough, wherein each leg receives a corresponding end cap and rail, and wherein for each corresponding end cap and rail, the end cap extends through the central bore of the leg and the one or more fins of the rail extend at least partially into a corresponding slot of the plurality of slots of the end cap to secure the rail and end cap with a corresponding leg of the plurality of legs of the connection member.
18. The frame system of claim 17, further comprising:
a plurality of connection members, each connection member including a plurality of legs; and
a plurality of junction nodes, each junction node including one connection member, and wherein the frame system further include a shelving member supported on one or more rails at adjacent junction nodes.