Modular assembly system
Methods and apparatus for modular combinations of structural elements ( 22 ) and connectors ( 30 ) that are sold as a set of unassembled or partially assembled parts ( 14 ), and are then transported and assembled by a consumer ( 10 ) having ordinary skill without special tools or expertise.
1 . An apparatus comprising:
a plurality of sub-assemblies;
each of said sub-assemblies including a panel and a rail; and
a joining means for providing a mechanical connection between two of said sub-assemblies;
each of said plurality of sub-assemblies being connected together to an adjacent sub-assembly with one of said joining means.
2 . An apparatus as recited in claim 1 , further comprising: a stile; said stile being attached to one of said panels.
3 . An apparatus as recited in claim 1 , in which each of said panels is attached to a pair of said rails and a pair of said stiles.
4 . An apparatus as recited in claim 1 , each of said sub-assemblies is attached to another adjacent sub-assembly; said pair of adjacent sub-assemblies being connected between a pair of said rails.
5 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies numbers two sub-assemblies.
6 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies numbers three sub-assemblies.
7 . An apparatus as recited in claim 1 , in which each of said joining means is attached to a pair of said rails.
8 . An apparatus as recited in claim 1 , in which said joining means comprises:
a first joining means element; and
a second joining means element;
said first and said second joining means elements for being aligned and then engaged to provide a mechanical connection.
9 . An apparatus as recited in claim 1 , in which said joining means includes:
a receiver; said receiver being mounted on one of said rails of a first of said plurality of sub-assemblies;
a bracket; said bracket being mounted in one of said rails of a second of said plurality of sub-assemblies;
said receiver and said bracket being generally aligned when said first and said second of said plurality of sub-assemblies are positioned for assembly;
said receiver and said bracket being engaged and then locked to hold said first and said second sub-assemblies in their proper place in a finished door.
10 . An apparatus as recited in claim 9 , in which two of said brackets are employed to engage one receiver.
11 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies are assembled by a manufacturer.
12 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies are assembled by a retailer.
13 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies are assembled by a contractor.
14 . An apparatus as recited in claim 1 in which said plurality of sub-assemblies are assembled by a consumer.
15 . An apparatus as recited in claim 1 , further comprising a jamb; said plurality of sub-assemblies being hung in said jamb by a manufacturer.
16 . An apparatus as recited in claim 1 , further comprising a jamb; said plurality of sub-assemblies being hung in said jamb by a retailer.
17 . An apparatus as recited in claim 1 , further comprising a jamb; said plurality of sub-assemblies being hung in said jamb by a contractor.
18 . An apparatus as recited in claim 1 , further comprising a jamb; said plurality of sub-assemblies being hung in said jamb by a consumer.
19 . An apparatus as recited in claim 1 , in which said plurality of sub-assemblies and said joining means are sold to a consumer in a box sold by a retail store.
20 . An apparatus as recited in claim 1 , in which said panel is manufactured from solid wood.
21 . An apparatus as recited in claim 1 , in which said panel is manufactured from solid wood.
22 . An apparatus as recited in claim 1 , in which said panel is manufactured from solid wood.
23 . An apparatus as recited in claim 1 , in which said panel is manufactured from plywood.
24 . An apparatus as recited in claim 1 , in which said panel is manufactured from particle board.
25 . An apparatus as recited in claim 1 , in which said panel is manufactured from paper-wrapped chipboard.
26 . An apparatus as recited in claim 1 , in which said panel is manufactured from paper.
27 . An apparatus as recited in claim 1 , in which said panel is manufactured from cloth.
28 . An apparatus as recited in claim 1 , in which said panel is manufactured from plastic.
29 . An apparatus as recited in claim 1 , in which said panel is manufactured from metal.
30 . An apparatus as recited in claim 1 , in which said panel is manufactured from glass.
31 . An apparatus as recited in claim 1 , in which one of said panels is decorated with a photo.
32 . An apparatus as recited in claim 1 , in which one of said panels is decorated with a pattern.
33 . An apparatus as recited in claim 1 , in which one of said panels is decorated with an image.
34 . An apparatus as recited in claim 1 , in which said rail is a telescoping rail.
35 . An apparatus as recited in claim 1 , in which said stile is a telescoping stile.
36 . An apparatus as recited in claim 1 , further comprising a plurality of telescoping rails.
37 . An apparatus as recited in claim 1 , further comprising a plurality of telescoping stiles.
38 . An apparatus as recited in claim 1 , in which said joining means is a hinge; said hinge for connecting a pair of said sub-assemblies.
39 . An apparatus as recited in claim 1 , in which said joining means is a hinge; said hinge being affixed to a pair of said rails.