Hybrid modular furniture and storage container unit
View Patent ↗In accordance with an embodiment, a hybrid modular furniture and container unit includes a base shell, a base core layer, and a set of base inner panels. The base shell has a shell bottom, a first shell wall, a second shell wall, a third shell wall, a fourth shell wall, and upper flaps associated with each of the respective walls. The base core layer has a core bottom, a first core wall, a second core wall, a third core wall, and a fourth core wall. The core layer is disposed within the base shell. The base inner panels include a first inner panel wall, a second inner panel wall, a third inner panel wall, and a fourth inner panel wall. The inner panel walls disposed within the shell and each upper flap is folded over a respective core wall and inner panel wall.
1. A hybrid modular furniture and container unit comprising:
a base shell comprising a shell bottom, a pair of shell side walls, a pair of shell end walls, and upper flaps associated with each respective shell wall;
a base core layer comprising a core bottom, a pair of core side walls and a pair of core end walls, the core layer disposed within the base shell; and
a set of base inner panels comprising a pair of inner panel side walls and a pair of inner panel end walls, the inner panel walls disposed within the base core layer and the base shell;
each upper flap is folded over a respective core wall and inner panel wall so as to envelop the respective core wall and inner panel wall;
the base core layer being a single piece of cross-shaped material such that each of the core side walls and each of the core end walls are foldably connected to the core bottom and independent from each other;
the base core layer being separate from the base shell and the set of base inner panels;
the inner panel walls being placed adjacent the inner walls of the base core layer to form double butt joints at each corner;
whereby each of the core side walls extends beyond one of the inner panel side walls and along an outer edge of each of the core end walls so that an outer edge of each of the core side walls is adjacent to one of the shell end walls of the base shell;
whereby each of the inner panel side walls extends along an outer edge of each of the inner panel end walls so that an outer edge of each of the inner panel side walls is adjacent to one of the core end walls;
whereby the outer edge of each of the core end walls engages an inner major planar surface of one of the core side walls; and
whereby the outer edge of each of the inner panel end walls engages an inner major planar surface of one of the inner panel side walls.
2. The hybrid modular furniture and container unit of claim 1 , wherein the upper flaps folded over the respective core walls and inner panel walls define a pair of unit side walls, a pair of unit end walls, and an internal cavity.
3. The hybrid modular furniture and container unit of claim 1 , wherein two of the four shell walls, two of the four core layer walls, and two of the four inner panel walls comprise a handle opening.
4. The hybrid modular furniture and container unit of claim 3 , further comprising a handle flap foldably connected to the shell over the handle opening therein.
5. The hybrid modular furniture and container unit of claim 1 , further comprising a first hole formed in one of the inner panel walls and a second opening formed in an opposite inner panel wall, the first and second openings for receiving a support.
6. The hybrid modular furniture and container unit of claim 5 , wherein the support is a peg.
7. The hybrid modular furniture and container unit of claim 5 , further comprising an internal member disposed on the support.
8. The hybrid modular furniture and container unit of claim 7 , wherein the internal member is one of a shelf, a bin, a tray and a drawer.
9. The hybrid modular furniture and container unit of claim 1 , wherein the base shell further comprises holes and cross-hatched slits formed in the base shell over the holes.
10. The hybrid modular furniture and container unit of claim 1 , wherein the shell comprises a transition portion connecting each shell wall with its respective upper flap.
11. The hybrid modular furniture and container unit of claim 1 , wherein the upper flaps are narrower than their respective shell walls.
12. The hybrid modular furniture and container unit of claim 1 , further comprising a lid.
13. The hybrid modular furniture and container unit of claim 12 , wherein the lid comprises:
a lid shell comprising a lid bottom, a first lid shell wall, a second lid shell wall, a third lid shell wall, a fourth lid shell wall, and lid upper flaps extending from each respective lid shell wall;
a lid core layer comprising a first lid core wall, a second lid core wall, a third lid core wall, and a fourth lid core wall, the lid core layer disposed within the lid shell; and
a lid panel disposed within the lid shell and surrounded by the lid core walls,
wherein each lid upper flap is folded over a respective lid core wall.
14. The hybrid modular furniture and container unit of claim 13 , wherein the lid upper flaps are sandwiched between a respective lid shell wall and the lid panel.
15. The hybrid modular furniture and container unit of claim 13 , wherein the lid further comprises an outer layer comprising a cork veneer.
16. The hybrid modular furniture and container unit of claim 13 , further comprising a detachable handle component connectable to the lid.
17. The hybrid modular furniture and container unit of claim 1 , wherein each of the upper flaps comprises a primary fold such that the upper flaps are hingedly connected to the shell walls at the primary fold; and wherein each of the upper flaps further comprises a secondary fold extending parallel to the primary fold and spaced therefrom.
18. The hybrid modular furniture and container unit of claim 1 , wherein the panel side walls and the panel end walls of the set of base inner panels are separate from each other.