Bullnose-edge structural member and method

1. A bullnose-edge structural member, comprising a laminated body of two opposing sheets sandwiching an intermediate layer, the body defining a first major planar surface and an opposing second major planar surface and opposing lateral sides, the body defining a pair of spaced-apart channels open to the first major surface and extending parallel to the lateral sides, and the laminated body folded along a line medial the channels whereby the second major planar surface defines a bullnose edge opposing an edge defined by the lateral sides that are aligned by the folding of the body.

2. The bullnose-edge structural member as recited in claim 1 , wherein the intermediate layer is corrugated paperboard.

3. The bullnose-edge structural member as recited in claim 2 , wherein the intermediate layer comprises a plurality of corrugated paperboard sheets laminated together.

4. The bullnose-edge structural member as recited in claim 1 , wherein the body further defines spaced-apart slots extending from the aligned lateral sides towards the opposing bullnose edge.

5. The bullnose-edge structural member as recited in claim 1 , wherein the body further defines opposing notched corners on the bullnose-edge.

6. The bullnose-edge structural member as recited in claim 1 , wherein the sheets are fibre board.

7. The bullnose-edge structural member as recited in claim 1 , wherein the channels extend through the intermediate layer to the opposing sheet.

8. A bookcase assembled from a plurality of bullnose-edge structural members, comprising:

two opposing side panels, each defining at least two spaced-apart slots; and

at least two shelf planks, each having opposing distal ends received in aligned respective slots of the opposing side panels,

the side panels and the shelf panels each comprising a laminated body of two opposing sheets sandwiching an intermediate layer, the body defining a first major planar surface and an opposing second major planar surface and opposing sides, the body defining a pair of spaced-apart channels open to the first major planar surface and extending parallel to the opposing sides, and the laminated body folded along a line medial the channels whereby the second major planar surface defines a bullnose-edge opposing an edge defined by the sides that are aligned together by the folding of the body.

9. The bookcase as recited in claim 8 , wherein the shelf planks each define opposing notched corners between the edge portion received in the slot of the side panel and the bullnose-edge of the shelf plank.

10. The bookcase as recited in claim 8 , wherein the sheets are fibre board.

11. The bookcase as recited in claim 8 , wherein the intermediate layer is corrugated paperboard.

12. The bookcase as recited in claim 11 , wherein the intermediate layer comprises a plurality of corrugated paperboard sheets laminated together.

13. The bookcase as recited in claim 8 , wherein the channels extend through the intermediate layer to the second sheet.

14. A method of making a bullnose-edge structural member, comprising the steps of:

(a) attaching a first sheet and a second sheet to a pair of opposing major faces of an interior layer to define a laminated body that also has opposing lateral sides;

(b) cutting in the laminated body a pair of spaced-apart channels open to the first sheet and extending parallel to the lateral sides; and

(c) folding the laminated body along a line medial the channels to align the lateral sides together,

whereby the second sheet defines a bullnose edge opposing the aligned lateral sides.

15. The method as recited in claim 14 , wherein the cutting step (b) cuts the channels through the intermediate layer to the second sheet.